Preventive Maintenance and Lubrication

Preventive Maintenance and Lubrication
mm1.fm.book Page -8 Thursday, August 24, 2006 12:29 PM
Maintenance Manual 1
Preventive Maintenance and Lubrication
Revised 08-06
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Service Notes
About This Manual
ArvinMeritor’s Customer Service Center
This manual provides maintenance intervals and procedures,
lubricant specifications, and product capacities for Meritor
components.
Call ArvinMeritor’s Customer Service Center at 800-535-5560.
Before You Begin
1.
Read and understand all instructions and procedures before
you begin to service components.
2.
Read and observe all Warning and Caution hazard alert
messages in this publication. They provide information that can
help prevent serious personal injury, damage to components,
or both.
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.
Technical Electronic Library DVD
The DriveTrain Plus™ by ArvinMeritor Technical Electronic Library
DVD contains product and service information for most Meritor and
Meritor WABCO products. Specify TP-9853.
How to Obtain Tools and Supplies
Specified in This Manual
Call ArvinMeritor’s Commercial Vehicle Aftermarket at
888-725-9355 to obtain Meritor tools and supplies.
Hazard Alert Messages and Torque
Symbols
WARNING
A Warning alerts you to an instruction or procedure that you
must follow exactly to avoid serious personal injury and
damage to components.
CAUTION
A Caution alerts you to an instruction or procedure that you
must follow exactly to avoid damage to components.
@ This symbol alerts you to tighten fasteners to a specified torque
value.
How to Obtain Additional Maintenance
and Service Information
On the Web
Visit Literature on Demand at meritorhvs.com to access product,
service, aftermarket, and warranty literature for ArvinMeritor’s truck,
trailer and specialty vehicle components.
Information contained in this publication was in effect at the time the publication was
approved for printing and is subject to change without notice or liability. Meritor Heavy
Vehicle Systems, LLC, reserves the right to revise the information presented or to
discontinue the production of parts described at any time.
Meritor Maintenance Manual 1 (Revised 08-06)
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Contents
pg. i
1
2
4
Asbestos and Non-Asbestos Fibers
Section 1: Introduction
Overview
Regularly-Scheduled Maintenance
Oil Lubricants
Viscosity
Oil Change Schedules
Oil Drain Conditions
National Lubricating Grease Institute (NLGI) Standards
Extreme Pressure (EP) Lubricants
19
23
24
Section 3: Clutches
8
9
12
13
14
15
17
18
25
26
27
28
30
33
Clutch Housing
Linkage
Lubrication Intervals and Specifications
Troubleshooting
Special Tools
34
Section 4: Drivelines
43
44
Technical Publications
How to Obtain Additional Maintenance and Service
Information
Description
RPL Series Permalube™ (Non-Greaseable)
Wing-Style Permalube™
Full-Round, Easy Service™, Wing-Style and 155R Series
(Greaseable)
Identification
Inspection
Driveline
End Yokes
Universal Joints
Center Bearings
Slip Yoke
Universal Joint Capscrews
Lubrication
RPL Series Permalube™ Driveline Universal Joint, Slip Yoke
and Splines
Standard/Conventional Driveline Universal Joint
Standard/Conventional Driveline Slip Yoke and Splines
Wing-Style Permalube™ Driveline Universal Joint
Wing-Style Greaseable Driveline Universal Joint
Wing-Style Permalube™ and Greaseable Driveline Slip Yoke
and Splines
Intervals
Inspection and Maintenance
Lubrication Intervals and Specifications
Troubleshooting
47
Section 5: Front Drive Steer Axles
Section 2: Bus and Coach
Technical Publications
How to Obtain Additional Maintenance and Service
Information
Description
Front Axles
Rear Axles
Center Axles
Important Information
Cam Brakes
Important Information
Stopmaster® Wedge Brakes
DiscPlus™ Brakes
T Series Parking Brake
Identification
Model Nomenclature
Inspection
Front Axles
Lubrication
King Pins
Tie Rod
Grease-Lubricated Wheel Bearings
Oil-Lubricated Wheel Bearings
Rear Axles
Inverted Portal Drive Axle
Planetary Drive Axles
Cam Brakes
T Series Parking Brake
Stopmaster® Brakes
Lubrication Intervals and Specifications
Stopmaster® Wedge Brakes
5
7
pg. 29
Technical Publications
How to Obtain Additional Maintenance and Service
Information
Description
Identification
Model Nomenclature
Inspection
When to Inspect the Clutch
Clutch Linkage
Internal Parts of the Clutch
Lubrication
Release Bearing
35
36
37
38
39
40
41
48
50
52
53
54
Technical Publications
How to Obtain Additional Maintenance and Service
Information
Description
Front Drive Steer Axles
Identification
Model Nomenclature
Front Drive Steer Axles
Front Drive Steer Axles, Prior Models
Inspection
Steering-Related Components
Steering Knuckle Vertical End Play
Upper and Lower Knuckle Bushings
Tie Rod Ends
Servicing the Tie Rod Ends
Why It’s Important to Inspect the Tie Rod Ends for Wear and
Allowable Movement at the Regularly-Scheduled Intervals
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Contents
pg. 55
57
61
62
63
Tie Rod Assembly Movement
Steering Arm Bolts
Sealed Hub Units
Carrier
Check and Adjust the Oil Level
Drain and Replace the Oil
Lubrication
Knuckle King Pins
Camshaft Retainer Bushing and Cam Bushing
Cross Tube End Assembly
Drive Axle Shaft Universal Joints
Axle Shaft Spline and Thrust Washer
Knuckle Bushing
Wheel Bearings
Tie Rod End
Steering Knuckle Sockets
Lubrication Intervals and Specifications
Troubleshooting
65
Section 6: Front Non-Drive Steer Axles
58
59
60
66
67
68
70
71
73
75
77
78
79
80
83
How to Obtain Additional Maintenance and Service
Information
Description
Identification
Model Nomenclature
Inspection
Parts
Steering Knuckle Vertical End Play
Upper and Lower King Pin Bushings
Unitized Wheel End
Tie Rod and Cross Tube Assembly
Department of Transportation Roadside Tie Rod Assembly
Replacement Criteria
Lubrication
Tie Rod End
King Pins
Ball Studs on the Steering Arm and the Tie Rod Arm Ends
Grease-Lubricated Wheel Bearings
Oil-Lubricated Wheel Bearings
Check and Adjust
Steering Arm Bolts
Tighten Draw Key Nuts
Lubrication Intervals and Specifications
Lubricant
Troubleshooting
85
Section 7: Brakes
86
87
Cam Brakes
Technical Publications
Description
Identification
Model Nomenclature
pg. 88
89
90
91
93
94
96
97
98
99
100
101
102
103
104
105
108
109
110
111
Important Information
Cam Brake Inspection Intervals and Procedures
On-Highway Linehaul Applications
Off-Highway Linehaul Applications
Q Plus™ LX500 and MX500 Cam Brakes with Automatic
Slack Adjusters
Do Not Lubricate the LX500 and MX500 Brakes and
Automatic Slack Adjuster Before the Specified Time or
Mileage Intervals
Inspection Procedure
Cam Brakes, All Models
Important Information
Commercial Vehicle Safety Alliance (CVSA) Guidelines
Cam Brake Lubrication Intervals and Procedures
Q Plus™ LX500 and MX500 Cam Brakes and Automatic
Slack Adjusters After the Specified Time or Mileage
Intervals
Cam Brake Tips
Approved Lubricants
Important Information
Cam Brake Troubleshooting
Diagnostic Charts
Air Disc Brakes
Technical Publications
Description
Features
Identification
Air Disc Brake Inspection Intervals and Procedures
Inspection Schedules
Important Information
Commercial Vehicle Safety Alliance (CVSA) Guidelines
Important Information
Checking the Adjusted Chamber Stroke Length on
DiscPlus™ DX195 and DX225 Air Disc Brakes
DiscPlus™ DX195 and DX225 Air Disc Brake Components
Air Disc Brake Model ADB 1560 Lubrication Intervals and
Procedures
Lubrication Procedures
Approved Lubricants
Important Information
Air Disc Brake Troubleshooting
Brake Diagnostic Charts
Important Information
DiscPlus™ DX195 and DX225 Air Disc Brakes
Automatic Slack Adjusters
Important Information
Technical Publications
Intervals
Procedures
At Brake Reline
Approved Lubricants
Anti-Seize Compound
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Contents
pg. 112
113
114
115
116
119
120
121
123
124
125
126
127
128
132
133
135
Important Information
Automatic Slack Adjuster Troubleshooting
Diagnostic Charts
Wedge Brakes
Technical Publications
Description
Identification
Important Information
Brake Adjustment Procedure
Inspection Procedure
Lubrication
Approved Lubricants
Important Information
Wedge Brake Troubleshooting
Diagnostic Charts
Four-Piston Quadraulic Disc Brakes
Technical Publications
Description
Identification
Four-Piston Quadraulic Disc Brake Inspection
Bleeding the Brake System
Four-Piston Quadraulic Disc Brake Troubleshooting
Diagnostic Charts
DuraPark® Hydraulic Drum Brakes
Technical Publications
Description
DuraPark® Hydraulic Brake Product Update
Adjustment Procedures
Brake Drums and Rotors
Technical Publications
Brake Drum Inspection and Failure Analysis
Brake Drum Wear Inspection
Clean the Mounting Surfaces
Brake Drum Procedures
Brake Drum Wear Conditions
Conditions That Can Affect Brake Drum Wear
Brake Drum Diagnostics
Rotors
Rotor Wear Inspection
Measuring the Thickness of the Rotor or Disc
136 Section 8: Rear Drive Axles
Technical Publications
How to Obtain Additional Maintenance and Service
Information
Description
Identification
138 Model Nomenclature
Axle Model Numbers and Designations
140 Inspection
Carrier
Oil Seals
pg. 141
142
143
144
145
146
150
Seal Test Procedure
Example 1: The Seal is not Leaking
Example 2: The Seal Appears to be Leaking
Example 3: The Seal is Leaking
Lubrication
Advanced Lube Axles
R-170 Axles Equipped with Traction Equalizer®
Limited Slip Friction Modifiers
Fill Plug Locations
Check and Adjust the Oil Level
Drain and Replace the Oil
Inter-Axle Assemblies with Separate Housings
Lubrication Intervals and Specifications
Lubrication Analysis Recommendations
Troubleshooting
All Rear Axles
151 Section 9: Suspensions
Technical Publications
How to Obtain Additional Maintenance and Service
Information
RideStarTM RHP Series Trailer Air Suspension Systems
Single-Axle System
152 Sliding Tandem System
153 Inspection
Single-Axle and Sliding Tandem Suspensions
154 Maintenance
Single-Axle and Sliding Tandem Suspensions
155 Upper Control Arm Bushing Periodic Inspection Guidelines:
All RideStar™ RHP Series Trailer Air Suspension Systems
156 Slider on Sliding Tandem Suspension System
157 RideStarTM RFS Series Trailer Air Suspension System
Ride Height
159 Tire Clearance
Maintenance
161 Inspect the Shock Absorbers
164 Section 10: Trailer Axles
Important Information
Technical Publications
How to Obtain Additional Maintenance and Service
Information
Description
Axle Models
Axle Designs
165 TB Series Trailer Axles with Unitized Wheel-End Assemblies
166 How to Identify Trailer Axles with Unitized Wheel Ends
How to Find the Model Number, Serial Number and Date of
Manufacture
167 What the Numbers Mean
Model Number
Serial Number
Date of Manufacture
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Contents
pg. 167 Model Nomenclature
Current Production Model Numbers
169 Section 11: Transfer Cases
Technical Publications
How to Obtain Additional Maintenance and Service
Information
Description
170 Model Nomenclature
171 Lubricant Temperatures
Meritor MTC-4208, MTC-4209 and MTC-4210 Series
Transfer Cases
Other Meritor Transfer Cases
Do Not Install API GL-5 Oils
Inspection
Magnets and Magnetic Drain Plugs
172 Breather
Seals
Check and Adjust the Oil Level
173 Drain and Replace the Oil
Intervals
174 Specifications
Capacities
175 Troubleshooting
181 Section 12: Transmissions
Technical Publications
How to Obtain Additional Maintenance and Service
Information
Description
182 Manual Transmissions
Engine Synchro Shift™ (ESS™) Transmission Shift System
SureShift™ Transmission
ZF-FreedomLine Transmission
Identification
183 Model Nomenclature
184 Intervals
Every 10,000 Miles (16 000 km) of Vehicle Operation
Every 50,000 Miles (80 000 km) of Vehicle Operation
(Approved Petroleum Base and Heavy-Duty Engine Oils)
Every 500,000 Miles (400 000 km) of Vehicle Operation
(Approved Full-Synthetic Oils)
185 Inspection
Oil Drain Conditions
Magnets and Magnetic Drain Plugs
Transmission Oil Coolers
Temperature Indicator
Check and Adjust the Oil Level
186 Inspection
Breather Vent Condition
Fastener Torque
187 Inspecting the Transmission for Leaks and Damage
Drain and Replace the Oil
Transmission Oil
Adjustment
Linkage for the Remote Control Assembly
pg. 188 Lubrication
Remote Control Assembly
ZF-FreedomLine Clutch Fork
Lubrication Intervals and Specifications
Approved Oil
189 Troubleshooting
On Manual Transmissions
Oil Leaks
On New Transmissions
Vibration
190 Noise
Operation Problems
Troubleshooting Leaks
191 Troubleshooting Vibrations
192 Troubleshooting Noises
193 Troubleshooting Operating Conditions
196 Section 13: Wheel Bearings and Wheel Ends
Technical Publications
How to Obtain Additional Maintenance and Service
Information
Conventional Wheel Ends
Description
197 Model Nomenclature
199 Oil-Lubricated Wheel Bearings
201 Grease-Lubricated Wheel Bearings
204 Important Information
Long-Life Wheel Ends
Front Non-Drive Steer Axles with Unitized Hubs
Identification
205 Model Nomenclature
Inspection Procedure
Inspection Intervals
Tools Required
206 Basic Inspection
Detailed Inspection
208 Replacement Hub Inspection
Install the Spindle O-Rings and Hubcaps
209 Trailer Axles with Long-Life Wheel Ends
210 Model Nomenclature
211 TB Series Trailer Axles with Unitized Hub Assemblies
212 TL Series Trailer Axles with Packaged Bearing Hub
Assemblies
214 Trailer Lubrication Intervals and Specifications
TRIAD™ Trailer Axle Wheel-End System
215 Wheel-End Equipment Checks
Studs and Nuts
219 Installing Double-Ended Metric Wheel Studs with 3/4-16 and
M22 x 1.5 Threads Onto Hub and Rotor Assemblies on
Axles Equipped with Meritor Air Disc Brake Model ADB
1560
Vehicles Equipped with ABS
220 Section 14: Specifications
Lubrication Intervals and Specifications
Grease Lubricants
221 Oil Lubricants
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Asbestos and Non-Asbestos Fibers
Figure 0.1
ASBESTOS FIBERS WARNING
NON-ASBESTOS FIBERS WARNING
The following procedures for servicing brakes are recommended to reduce exposure to
asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are
available from ArvinMeritor.
The following procedures for servicing brakes are recommended to reduce exposure to
non-asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data
Sheets are available from ArvinMeritor.
Hazard Summary
Hazard Summary
Because some brake linings contain asbestos, workers who service brakes must understand the
potential hazards of asbestos and precautions for reducing risks. Exposure to airborne asbestos
dust can cause serious and possibly fatal diseases, including asbestosis (a chronic lung disease)
and cancer, principally lung cancer and mesothelioma (a cancer of the lining of the chest or
abdominal cavities). Some studies show that the risk of lung cancer among persons who smoke
and who are exposed to asbestos is much greater than the risk for non-smokers. Symptoms of
these diseases may not become apparent for 15, 20 or more years after the first exposure to
asbestos.
Accordingly, workers must use caution to avoid creating and breathing dust when servicing
brakes. Specific recommended work practices for reducing exposure to asbestos dust follow.
Consult your employer for more details.
Most recently manufactured brake linings do not contain asbestos fibers. These brake linings may
contain one or more of a variety of ingredients, including glass fibers, mineral wool, aramid fibers,
ceramic fibers and silica that can present health risks if inhaled. Scientists disagree on the extent
of the risks from exposure to these substances. Nonetheless, exposure to silica dust can cause
silicosis, a non-cancerous lung disease. Silicosis gradually reduces lung capacity and efficiency
and can result in serious breathing difficulty. Some scientists believe other types of non-asbestos
fibers, when inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic
fiber dust are known to the State of California to cause lung cancer. U.S. and international
agencies have also determined that dust from mineral wool, ceramic fibers and silica are potential
causes of cancer.
Accordingly, workers must use caution to avoid creating and breathing dust when servicing
brakes. Specific recommended work practices for reducing exposure to
non-asbestos dust follow. Consult your employer for more details.
Recommended Work Practices
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 and 1.0 f/cc averaged over
a 30-minute period. Scientists disagree, however, to what extent adherence to the maximum
allowable exposure levels will eliminate the risk of 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 allowable levels:
DANGER: ASBESTOS
CANCER AND LUNG DISEASE HAZARD
AUTHORIZED PERSONNEL ONLY
RESPIRATORS AND PROTECTIVE CLOTHING
ARE REQUIRED IN THIS AREA.
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter
approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, beginning
with the removal of the wheels.
3. Procedures for Servicing Brakes.
a.
Enclose the brake assembly within a negative pressure enclosure. The enclosure should be
equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the
HEPA vacuum to loosen and vacuum residue from the brake parts.
b. As an alternative procedure, use a catch basin with water and a biodegradable, nonphosphate, water-based detergent to wash the brake drum or rotor and other brake parts.
The solution should be applied with low pressure to prevent dust from becoming airborne.
Allow the solution to flow between the brake drum and the brake support or the brake rotor
and caliper. The wheel hub and brake assembly components should be thoroughly wetted to
suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts
clean with a cloth.
c. If an enclosed vacuum system or brake washing equipment is not available, employers may
adopt their own written procedures for servicing brakes, provided that the exposure levels
associated with the employer’s procedures do not exceed the levels associated with the
enclosed vacuum system or brake washing equipment. Consult OSHA regulations for more
details.
d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use with
asbestos when grinding or machining brake linings. In addition, do such work in an area with
a local exhaust ventilation system equipped with a HEPA filter.
e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA
filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents,
flammable solvents, or solvents that can damage brake components as wetting agents.
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet
wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty
vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved
by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter, wet the filter with a fine
mist of water and dispose of the used filter with care.
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke.
Shower after work. Do not wear work clothes home. Use a vacuum equipped 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.
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care,
such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste
disposal.
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.
Recommended Work Practices
1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other
operations to reduce risks to unprotected persons.
2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for 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-asbestos brake linings be kept
below 1.0 f/cc as an 8-hour time-weighted average. Scientists disagree, however, to what extent
adherence to these maximum allowable exposure levels will eliminate the risk of disease that can
result from inhaling non-asbestos dust.
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) filter
approved by NIOSH or MSHA, if the exposure levels may exceed OSHA or manufacturers’
recommended maximum levels. Even when exposures are expected to be within the maximum
allowable levels, wearing such a respirator at all times during brake servicing will help minimize
exposure.
3. Procedures for Servicing Brakes.
a.
Enclose the brake assembly within a negative pressure enclosure. The enclosure should be
equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the
HEPA vacuum to loosen and vacuum residue from the brake parts.
b. As an alternative procedure, use a catch basin with water and a biodegradable, nonphosphate, water-based detergent to wash the brake drum or rotor and other brake parts.
The solution should be applied with low pressure to prevent dust from becoming airborne.
Allow the solution to flow between the brake drum and the brake support or the brake rotor
and caliper. The wheel hub and brake assembly components should be thoroughly wetted to
suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts
clean with a cloth.
c. If an enclosed vacuum system or brake washing equipment is not available, carefully clean
the brake parts in the open air. Wet the parts with a solution applied with a pump-spray
bottle that creates a fine mist. Use a solution containing water, and, if available, a
biodegradable, non-phosphate, water-based detergent. The wheel hub and brake assembly
components should be thoroughly wetted to suppress dust before the brake shoes or brake
pads are removed. Wipe the brake parts clean with a cloth.
d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when grinding or
machining brake linings. In addition, do such work in an area with a local exhaust ventilation
system equipped with a HEPA filter.
e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA
filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents,
flammable solvents, or solvents that can damage brake components as wetting agents.
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet
wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty
vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved
by NIOSH or MSHA, to minimize exposure. When you replace a HEPA filter, wet the filter with a
fine mist of water and dispose of the used filter with care.
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke.
Shower after work. Do not wear work clothes home. Use a vacuum equipped 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.
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care,
such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste
disposal.
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.
Meritor Maintenance Manual 1 (Revised 08-06)
i
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1
1 Introduction
Overview
1 Introduction
This manual provides maintenance and lubrication information for
Meritor-produced components, including inspection and service
intervals, procedures, grease and oil specifications and product
capacities. Troubleshooting information is also provided to assist in
diagnosing customer concerns. Following these guidelines will
enable you to correctly lubricate and maintain components, and
correct issues to help ensure maximum component life.
Viscosity
CAUTION
Use the correct viscosity lubricants. Do not lower the viscosity
of lubricants by adding thinning agents, such as kerosene,
gasoline or other dilutents. Damage to components will result.
앫 Always follow recommended maintenance intervals and
procedures.
Select the correct viscosity oil for a specific component from the
tables in each section of this manual. When more than one lubricant
is listed, choose an oil viscosity that is suitable for the expected
outside temperature.
앫 Always use the specified oil or grease lubricant from a
manufacturer that provides quality products and complete
application instructions.
Oil viscosity grades and classifications are provided by the Society
of Automotive Engineers (SAE) and the American Petroleum Institute
(API).
To obtain additional maintenance and service information for
components included in this manual, refer to the Service Notes page
on the front inside cover of this manual.
Regularly-Scheduled Maintenance
Internal components can shed fine metal wear particles at a
steady rate, especially during the break-in period. If wear
particles, moisture and other contaminants are allowed to circulate
in the lubricant, the components will wear at a faster rate than
normal.
Regularly-scheduled maintenance using the specified lubricants
will help to ensure maximum component performance and life.
Oil Lubricants
앫 Use multigrade oils when vehicles operate in both cold and warm
weather between oil changes.
앫 Use low viscosity single grade oils only in cold climates. Single
grade 75W oils are not approved for use in drive axles where
ambient or outside temperatures exceed 40° F (4° C).
앫 Use multigrade oil for drive axles only. The hypoid gearing
requires a GL-5 oil with Extreme Pressure (EP) additives to
provide adequate lubricant film protection that prevents gear
failure.
Oil Change Schedules
To determine an oil change schedule, take an oil sample at a
specified interval or mileage recommendation. Analyze the sample
to establish a schedule.
There are three types of oil lubricants: petroleum, full-synthetic and
semi-synthetic. Both full-synthetic and semi-synthetic oils retain
their lubrication properties longer than petroleum oil.
However, service duty will often dictate when to change the oil,
regardless of mileage or a previously-established schedule.
앫 Petroleum oil is derived from crude oil. Crude petroleum oil also
yields combustible fuels and a wide range of petroleum
chemicals.
Oil Drain Conditions
앫 Full-synthetic oil uses a man-made-base oil with predictable
physical properties. Full-synthetic oil contains no refined
petroleum-base fluids.
Drain and replace used differential oil that does not meet the
following used-oil analyses. Replace the drained oil with the oil
specified for hypoid drive axle use.
앫 Semi-synthetic oil contains a mixture of petroleum-base and
synthetic fluids that can help extend service intervals, improve
cold weather properties and reduce volatility.
Meritor recommends that you perform a lubricant analysis at
every regularly-scheduled preventive maintenance interval.
Differential Oil (Hypoid Gear Oils)
Meritor Maintenance Manual 1 (Revised 08-06)
1
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1 Introduction
Table A: Used-Oil Analyses (ppm = parts per million)
Iron (Fe)
If the level is 1000-1500 ppm, resample the
oil. If resampling indicates that the iron level is
above 1000 ppm, drain and replace the oil.
If the level is above 1500 ppm, drain and
replace the oil.
Silicon (Si)
Water (H2O)
Phosphorus (P)
Toluene
Insolubles
If the level is greater than 100 ppm, drain and
replace the oil.
If the level is greater than 0.3%, drain and
replace the oil.
If the level is less than 900 ppm, it is possible
that the oil is not a GL-5 gear oil. Contact the
lubricant manufacturer or Meritor Materials
Engineering to determine the expected
phosphorus level of a new oil sample. Only
GL-5 type gear oils are approved for use in
Meritor differentials.
If the level is greater than 0.100 wt.%, drain
and replace the oil.
Manual Transmission Oils
If used transmission oil analyses indicate that any one of these
criteria is not met, drain the used oil and replace it with an oil that is
recommended for manual transmissions.
Do not mix different types of grease. Incompatible greases may
reduce the lubricating ability of the greases.
An important property of a grease is its dropping point, the
temperature where grease changes from a semi-solid state to a
liquid state. However, the operating temperature of a specific grease
is not determined solely by the dropping point. Other properties such
as resistance to change in consistency and chemical deterioration at
high temperatures must be considered.
National Lubricating Grease Institute (NLGI)
Standards
The National Lubricating Grease Institute (NLGI) classifies and
grades grease lubricants according to consistency and the
application for which it is used.
The NLGI also issues licensed labels that identify approved grease
lubricant applications.
Extreme Pressure (EP) Lubricants
CAUTION
Do not use multi-viscosity or Extreme Pressure (EP) GL-5 gear
oils in a manual transmission or transfer case. Damage to the
transmission will result.
Iron (Fe)
If the level is greater than 500 ppm, drain
and replace the oil.
Extreme Pressure lubricants are often identified by the abbreviation
EP. Extreme Pressure lubricants contain additives that provide extra
anti-wear protection to heavily-loaded parts. EP greases or EP oils
are required in various applications. Figure 1.1.
Silicon (Si)
If the level is greater than 100 ppm, drain
and replace the oil.
Approved hypoid gear oils contain EP additives that protect against
tooth scoring and surface fatigue.
Table B: Used-Oil Analyses (ppm = parts per million)
Water (H2O)
If the level is greater than 0.3%, drain and
replace the oil.
Grease Lubricants
Grease lubricants contain three substances: oil, thickener base and
additives. The oil lubricates. The thickener or base holds the oil in
place and releases it to provide the necessary lubrication. The
thickener may be a simple or complex soap (lithium, calcium,
aluminum, etc.), organic (polyurea) or inorganic (clay). The additives
enhance the characteristics of the oil and thickener. Extreme
Pressure (EP) additives help prevent scoring, galling and welding
of moving parts.
2
Meritor Maintenance Manual 1 (Revised 08-06)
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1
1 Introduction
Figure 1.1
Labels licensed by the
NLGI identify approved
grease applications.
1003313a
Figure 1.1
Meritor Maintenance Manual 1 (Revised 08-06)
3
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2 Bus and Coach
2 Bus and Coach
Hazard Alert Messages
Description
Read and observe all Warning and Caution hazard alert messages
in this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
Meritor provides a wide selection of components to the transit bus
and coach industry suited to the latest vehicle designs as well as for
traditional applications. These include:
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
Technical Publications
How to Obtain Additional Maintenance and
Service Information
Refer to the publications in Table C. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
Table C: Publications
Model
Manual
Bus and Coach Front Axles
Maintenance Manual 23
Bus and Coach Rear Axles
Maintenance Manual 23A
Bus and Coach Brakes
Maintenance Manual 23B
Bus and Coach Gear Drive
Drop Box for Axle Models
S-162 and -163; SC-164
and -165
Maintenance Manual 23C
Bus and Coach Inverted Portal
Drive Axle
Maintenance Manual 23D
Bus and Coach Planetary
Drive Axle/Model RC-26-633
Maintenance Manual 23E
Bus and Coach RDC Wedge
Brakes
Maintenance Manual 23F
Bus and Coach Electric
Drive Axle
Maintenance Manual
MM-9905-G
앫 Front non-drive steer axles — 17100, 17101, 17111, FH 941,
FH 945 and FH 946
앫 Rear drive axles — 59000 Series, 61000 Series, 71000 Series
and RC-23-160
앫 Center non-drive axles — 61000 Series, 71000 Series and
RC-26-700
앫 Inverted portal drive axles — RC-26-720 and RC-27-720
앫 Planetary drive axle — RC-26-633
앫 Stopmaster® wedge brakes — RDC Series
앫 Cam brakes — Q Series, Q Plus™, Cast Plus™ and W Series
앫 Disc brakes — DiscPlus™ DX195 and DX225
앫 Parking brake — T Series
Front Axles
Seven Meritor front non-drive steer axle models are available for
buses and coaches. Models 17110 and 17111 have an I-beam
construction. Models 17100 and 17101 have a rectangular beam in
the center. Figure 2.1. Models FH 941, FH 945 and FH 946 have an
I-beam construction. Figure 2.2 and Figure 2.3.
Figure 2.1
4003473a
Figure 2.1
Figure 2.2
4003474a
Figure 2.2
4
Meritor Maintenance Manual 1 (Revised 08-06)
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2 Bus and Coach
2
61000 Series
Figure 2.3
The Meritor 61000 Series drive axles have the following features.
Figure 2.5.
앫 The single-reduction carrier is combined with a hypoid drive
pinion and a ring gear.
앫 Optional double-reduction carriers are also available.
4003475a
4004375a
Figure 2.3
앫 The housing is designed with replaceable axle tubes at the wheel
spindles.
앫 The housing has weld-on torque rod brackets.
Rear Axles
Figure 2.5
The Meritor bus and coach rear drive axles are available in the
59000, 61000 and 71000 Series and RC-23-160.
59000 Series
The Meritor 59000 Series drive axles have the following features.
Figure 2.4.
앫 Spiral bevel gearing is used in an angle drive carrier. The pinion
is at a 63-degree angle to the axis of the axle shafts.
앫 Optional conventional single-reduction and double-reduction
carriers with hypoid gearing are also available.
4001372a
Figure 2.5
71000 Series
앫 A driveline parking brake is installed on the flange of some angle
drive carriers.
The Meritor 71000 Series drive axles have the following features.
Figure 2.6.
앫 The housing is designed with replaceable axle tubes at the wheel
spindles.
앫 The single-reduction carrier is combined with a hypoid drive
pinion and a ring gear.
앫 The housing is designed with replaceable axle tubes at the wheel
spindles.
Figure 2.4
앫 The housing has bolt-on torque rod brackets.
앫 The axles are equipped with either S-cam or DiscPlus™ brakes.
Figure 2.6
4001371a
Figure 2.4
4001364a
Figure 2.6
Meritor Maintenance Manual 1 (Revised 08-06)
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2 Bus and Coach
RC-23-160 Series
Figure 2.8
The RC-23-160 Series drive axles have the following features.
Figure 2.5.
C
B
A
B
C
앫 The single-reduction carrier is combined with a hypoid drive
pinion and a ring gear.
앫 The housing is designed without replaceable axle tubes at the
wheel spindles.
A CENTER HOUSING
MODULE
B HELICAL GEAR
HOUSING MODULE
Inverted Portal Drive Axle
The Meritor RC-26-720 and RC-27-720 inverted portal drive axles
are double-reduction axles. The differences between the two
models are the suspension bracketry configuration and the
mounting of the brake chambers and automatic slack adjusters.
Both axles feature spiral bevel and helical forged gearing with
industry-standard wheel ends. All gears are ground to minimize the
potential for gear noise. Figure 2.7.
Figure 2.7
C WHEEL-END MODULE
MODULES A AND
PRE-ASSEMBLED
SEPARATELY
B
EASIER ASSEMBLY
PROCESS AND FIELD
SERVICEABILITY
4000885a
Figure 2.8
Planetary Drive Axle
The Meritor RC-26-633 is a double-reduction axle. The first
reduction is in the carrier and the second reduction is in the wheel
end. This allows for a smaller carrier ring gear and a lower bus floor.
Special ground gearing in both the carrier and wheel end produces
quieter operation. Figure 2.9.
Figure 2.9
4000884a
Figure 2.7
4002874a
The axles feature a modular design that consists of five separate
units:
앫 One center housing
앫 Two helical gear housings
앫 Two wheel ends
This modular design allows each module to be assembled and
serviced independently for easier maintenance. Figure 2.8.
6
Meritor Maintenance Manual 1 (Revised 08-06)
Figure 2.9
The axle is equipped with Meritor Cast Plus™ cam brakes with a
16.5-inch diameter and 8.62-inch wide heavy-duty cast shoes.
The axle also is equipped with the anti-lock braking system sensor
and tooth ring.
mm1.fm.book Page 7 Thursday, August 24, 2006 12:29 PM
2 Bus and Coach
Center Axles
The Meritor bus and coach center axles are available in the
61000 and 71000 Series and RC-26-700.
61000 and 71000 Series
The 61000 and 71000 Series center axles have the following
features.
앫 Center axles are identical to the 61000 and 71000 Series drive
axles except without carriers or axle shafts.
앫 The spindle ends are capped so only the wheel end is filled with
lubricant.
앫 A hubcap is used to keep lubricant in the wheel end instead of
an axle shaft. Figure 2.10.
Figure 2.10
2
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ASA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
For Meritor brake adjustment, refer to the brake adjustment tables
in Section 7. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
Cam Brakes
Meritor cam brakes are air-actuated, cam-operated, double shoe
brakes with each shoe mounted on a separate anchor pin. The
brakes are available with automatic or manual adjustment and can
be assembled with auxiliary spring brakes.
There are three types of cam brakes for buses and coaches:
Q Series and Q Plus™, Cast Plus™ and W Series.
Q Series and Q Plus™
4001374a
Figure 2.10
RC-26-700 Series
The RC-26-700 Series center axles feature the following.
The Q Series and Q Plus™ brake shoe has an open end on the
anchor pin ends for “quick change” service. An anchor pin fastens
each brake shoe to the spider. The linings are fastened to the brake
shoes with rivets. Two retaining springs and one return spring hold
the shoes together on the spider. Figure 2.12.
Figure 2.12
Q AND Q-PLUS™ SERIES
앫 Tubular deep-drop axles are designed for low floor applications.
Figure 2.11.
Figure 2.11
4001453a
Figure 2.12
4001365a
Figure 2.11
Important Information
Meritor automatic slack adjusters (ASAs) should not need to be
manually adjusted in service. ASAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ASA,
brake actuator or other system components.
Q Series brakes are available in 16.5-inch diameter with a 10-inch
width and 0.75-inch tapered brake lining. A 15-inch diameter is
available for front non-drive applications.
Q Plus™ brakes are available in 16.5-inch (419 mm) diameter with
5-, 6-, 7- and 8.625-inch (127, 152, 178 and 219 mm) widths.
The tapered brake linings are 0.75-inch (19.05 mm) thick.
Meritor Maintenance Manual 1 (Revised 08-06)
7
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2 Bus and Coach
Cast Plus™
Important Information
The Cast Plus™ brake is designed for heavy-duty, off-highway and
people-mover applications. A redesigned S-cam and heavy-duty
shoe return spring allow additional shoe travel. An improved
camshaft bushing contributes to longer service life. The Cast Plus™
brake uses Q Plus™ brake linings and the P Series brake shoe
design. Figure 2.13.
Meritor automatic brake adjusters (ABAs) should not need to be
manually adjusted in service. ABAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ABA,
brake actuator or other system components.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
Figure 2.13
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ABA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
4001450a
Figure 2.13
Cast Plus™ brakes are available in 16.5-inch (419 mm) diameter
with 6- and 8.625-inch (152 and 219 mm) widths.
W Series
The W Series brake has anchor pins that fasten the brake shoe to
the spider. The anchor pins can have a straight or tapered design.
The spider can have an integral or separate cam bracket. The brake
shoes are fastened to the linings with bolts. Figure 2.14.
W Series brakes are available in 14.5-inch (368 mm) diameter with
5-, 6-, 8- and 10-inch (127, 152, 203 and 254 mm) widths.
Figure 2.14
W SERIES
For Meritor brake adjustment, refer to the brake adjustment tables
in Section 7. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
Stopmaster® Wedge Brakes
Meritor Stopmaster® brakes are wedge-actuated air brakes that are
used on buses. The clearance between the drum and the linings is
automatically adjusted. The brake support is a cast spider with
plunger, actuation, housings. Stopmaster® brakes are available in
the RDC Series.
RDC Series
The RDC Series brake is available in a 15.125-inch (384 mm)
diameter. The brake shoes are available in 6-inch (152 mm) widths
for front brakes and 10-inch (254 mm) widths for rear brakes.
Air chambers on the rear brakes are larger than the air chambers on
the front brakes. Bolts and nuts are used to fasten the linings to the
shoes. The linings are tapered at each end of the shoe. The shoes
engage the plungers at the tab on the top of each plunger assembly.
The anchor plunger is a two-piece assembly that uses an anchor
housing and a lock nut.
DiscPlus™ Brakes
4001454a
Figure 2.14
8
Meritor Maintenance Manual 1 (Revised 08-06)
DiscPlus™ DX195 and DX225 air disc brakes are optional on
FF and FG bus and coach front steer axles. Brakes feature sealed
calipers lubricated to protect components that actuate the brake.
The brake is comprised of a lightweight single-piece cast caliper
supported on twin fully seated slide pins fixed to a mounting saddle.
Figure 2.15.
mm1.fm.book Page 9 Thursday, August 24, 2006 12:29 PM
2 Bus and Coach
2
Identification
Figure 2.15
Model Nomenclature
Front Axles
The axle model identification plate is located on the axle center. Use
the model number to obtain the correct parts from Meritor.
Figure 2.17 and Figure 2.18.
Figure 2.17
Identification
Number
4002891a
17101 WX-69
Figure 2.15
Front Axle
Indentification Number
T Series Parking Brake
The 59000 Series parking brake is a Meritor T Series brake installed
on the drive pinion bearing cage in the differential carrier.
앫 An air chamber with an automatic slack adjuster is attached to
the parking brake camshaft.
Specification
Variation
Brake Usage
4002888a
Figure 2.17
앫 A brake drum is installed onto the yoke flange.
앫 The brake assembly has an outer diameter of 12-inches (304 mm).
Figure 2.18
Identification
Number
앫 The brake shoes are 4.5-inches (114 mm) wide. Figure 2.16.
FH 945 L X 3
Figure 2.16
INLET
PORT
PARKING BRAKE
CHAMBER
Front Axle
Indentification Number
SLACK
ADJUSTER
Specification
Variation
Brake Usage
JAM
NUT
4002889a
Figure 2.18
CAGING
SLEEVE
PUSH
ROD
ADJUSTING
BOLT
PARKING
BRAKE
CLEVIS
Figure 2.16
Meritor Maintenance Manual 1 (Revised 08-06)
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2 Bus and Coach
Rear Axles
Figure 2.21
An identification tag is located on the axle housing or the differential
carrier. Use the model number and the ratio number marked on the
tag to obtain replacement parts. Figure 2.19.
61000 SERIES
71000 SERIES
IDENTIFICATION TAG
71-177 Carrier,
28,660 lb. (13 000 kg)
Model No. ...........................
Customer No. .....................
Plant ..........................
Date ...........................
4001376a
Gearing Type
1 — Single Reduction
2 — Two Speed
3 — Double-Reduction
Helical
0 — No Carrier or Axle
Shaft
Assembly
Variation
Type Brake
Overall
2 — 96"
3 — 102"
Housing
4 — Standard
5 — Large Box Section
6 — Cast Housing
4001443a
Figure 2.19
Figure 2.20 and Figure 2.21 explain the model number designation
for the 59000, 61000 and 71000 Series axles.
Figure 2.20
59000 SERIES
Axle Identification
Number
Assembly
59722W 123
Series and Capacity
25,000 lb. (11 340 kg)
Gearing Type
7 — Single Reduction
8 — Double Reduction
0 — No Reduction
Type Brakes
Overall
2 — 96"
3 — 102"
Housing
2 — Std. Angle Drive 63˚
3 — New Generation Angle Drive
4 — Housing Altered to Accommodate
“R” Series Carriers
5 — Large Housing Box Size
4001442a
Figure 2.20
10
61142 RDC 123
Series and Capacity
61-160 Carrier,
26,000 lb. (11 793 kg)
Figure 2.19
Serial No. .......................
Ratio ...............................
Axle Identification
Number
Meritor Maintenance Manual 1 (Revised 08-06)
Figure 2.21
mm1.fm.book Page 11 Thursday, August 24, 2006 12:29 PM
2 Bus and Coach
2
The RC-23-160 coach rear axle, RC-26-720 and RC-27-720
inverted portal axles and RC-26-633 planetary drive axle are
identified by a letter and number system that provides information
about the specific axle model. Figure 2.22. The first seven positions
of the designation identify a basic axle model. The second group of
letters and numbers identify complete axle specifications.
Figure 2.22
RC-23-160 SERIES
Gearing Type
1 — Single Speed
2 — Two Speed
3 — Helical Double Reduction
4 — Salisbury Single Speed
5 — Planetary Double Reduction
6 — Hub Reduction
7 — Portal Reduction
Manufacturing Location
A — Australia
B — Brazil (Braseixos)
C — India
D — Mexico (Dirona)
E — Europe (C.V.C.)
M — Europe (Maudslay)
N — U.S.A.
Nominal Axle Load
Rating (GAWR)
In thousands of pounds.
Meritor
(Rockwell)
R C-23-1 6 0 N R R F* 123
Axle Type
C — Single Rear Drive Axle, Coach
D — Forward-Rear Axle of a Drive
Tandem with Inter-Axle Differential
N — Forward-Rear Axle of a Drive
Tandem or Tridem without
Inter-Axle Differential
P — Forward-Rear Axle of a Drive
Tandem with Inter-Axle Differential
and Pump
R — Rear-Rear Axle of a Drive Tandem
S — Single Rear Drive Axle
T — Tandem Drive Axle Set
Z — Tridem Drive Axle Set
Carrier Type
Carrier size. Larger numbers
indicate a higher GCW-rated
carrier.
Main Differential Nest Type
B — Special Differential
C — Driver-Controlled Differential
Lock
F — Standard Differential
H — High Traction® Differential
N — NoSPIN®
R — Rigid Axle-Less Carrier
Brake Type
C — Air Disc Brake
D — RDA Stopmaster® Wedge Brake
(Dual Air Chambers)
E — RDH Stopmaster® Wedge Brake
(Dual Hydraulic Cylinders)
F — RSH Stopmaster® Wedge Brake
(Single Hydraulic Cylinder)
L — Q Plus™ Cam Brake
N — None
P — P Series Cam Brake
Q — Q Series Cam Brake
R — Cast Plus™ Cam Brake
S — RSA Stopmaster® Wedge Brake
(Single Air Chamber)
T — T Series Cam Brake
W — W Series Cam Brake
Axle Specification Number
Identifies specific customer axle
configurations (variations from the original
axle design). For information about the
variation, see the Bill of Materials for that
specific axle model.
Hub Type
A — Aluminum
C — Cast Spoke Wheel
F — Ferrous
N — None
Axle Design Variation
Indicates axle design level
or variation.
*NOTE: This position will be used to
designate hub only until more than three
digits are required to designate axle
specification.
4001444a
Figure 2.22
Meritor Maintenance Manual 1 (Revised 08-06)
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2 Bus and Coach
Cam Brakes
Figure 2.25
AXLE
IDENTIFICATION
NUMBER
The brakes can be identified by a code on the axle identification
plate. Figure 2.23.
Figure 2.23
17010-WX-69
59733-RDC-18
BRAKE
IDENTIFICATION
NUMBER
BRAKE
IDENTIFICATION
NUMBER
4001455a
Figure 2.23
When parts are replaced, the correct parts must be used. Part
numbers are found on the top of the camshaft, on the brake spider,
on the brake shoes and on the air chamber bracket.
Wedge Brakes
Meritor Stopmaster® brakes are identified by a three-letter code on
the axle identification plate. Figure 2.24 and Figure 2.25.
Figure 2.24
RDC
4002873a
Figure 2.25
When using replacement parts, verify that the correct parts are
used. Part numbers are found on the brake spider and the brake
shoes.
Inspection
Front Axles
Inspect components during regularly scheduled maintenance
intervals to ensure correct operation and maximize the life of the
parts.
WARNING
C = COACH
D = DOUBLE
ACTUATED
MERITOR
STOPMASTER®
WEDGE BRAKE
4002872a
Figure 2.24
Replace damaged or out-of-specification axle components. Do
not bend, repair or recondition axle components by welding or
heat-treating. A bent axle beam reduces axle strength, affects
vehicle operation and voids Meritor’s warranty. Serious
personal injury and damage to components can result.
Fasteners
Verify that all fasteners are tightened to the specified torque. Use a
torque wrench to check the torque in a tightening direction. As soon
as the fastener starts to move, record the torque. Correct if
necessary. Replace any worn or damaged fasteners.
Wear and Damage
Inspect the parts of the axle for wear and damage. Look for bent or
cracked parts. Replace all worn or damaged parts.
12
Meritor Maintenance Manual 1 (Revised 08-06)
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2 Bus and Coach
2
Pivot Points
Tie Rod
Verify that looseness does not exist at the pivot points. Verify that
the pivot points are lubricated.
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Set the parking brake.
Operation
2.
Verify that the tires touch the ground. Do not raise the vehicle.
Verify that all the parts move freely through the complete turning
radius.
3.
Clean and remove the oil grease fittings prior to lubrication.
4.
Apply lubricant at each grease fitting until new lubricant flows
from the boot.
Tire Wear
Inspect the tires for wear patterns that indicate suspension damage
or misalignment.
Grease-Lubricated Wheel Bearings
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving.
Check the torque every 200,000 miles (320 000 km).
2.
Raise the vehicle so that the wheels are off the ground.
Support the vehicle with safety stands.
Lubrication
3.
Remove the tire and wheel assembly. Remove and
disassemble the hub.
4.
Use the correct cleaning solvent to remove the old grease from
all parts. Discard the seals. Inspect the wheel bearings for
wear or damage. Replace worn or damaged bearings.
5.
Before installing the wheel bearings, lubricate the bearing
journals on the spindle with the grease that is used for the
bearings. Figure 2.27.
Steering Arm Bolts
King Pins
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Set the parking brake.
2.
Verify that the tires touch the ground. Do not raise the vehicle.
3.
Clean all grease fittings prior to lubrication.
4.
Apply lubricant to the top fitting until new lubricant purges from
between the upper shim pack and thrust bearing seal.
Figure 2.26.
Figure 2.27
TYPICAL GREASE-LUBRICATED WHEEL BEARINGS
LUBE
Figure 2.26
TOP GREASE FITTING
SIDE GREASE
FITTING
1003337a
Lube must come
from here.
Figure 2.27
1000327c
Figure 2.26
5.
Apply lubricant to the bottom fitting until new lubricant purges
and fills the thrust bearing.
6.
Use a pressure packer to force the specified grease from the
large end of the cones into the cavities between the rollers and
cage. Pack the hub between the bearing cups with grease to
the level of the smallest diameter of the cups.
앫 If a pressure packer is not available: Grease the
bearings by hand.
Meritor Maintenance Manual 1 (Revised 08-06)
13
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2 Bus and Coach
7.
Install the inner and outer bearing cones into the cups in the
hubs. The bearing cups must be pressed tight against the
shoulder in the hubs.
8.
Install new wheel seals into the hubs.
9.
Install the hub and the wheel and tire assembly. Install the
outer wheel bearing cone into the hub. Install the adjusting nut.
Drain and Replace the Oil
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. The axle lubricant capacity changes
when the drive pinion angle changes.
2.
Place a drain pan under the axle. Remove the drain plug from
the bottom of the axle housing. Drain the lubricant. Install the
drain plug and tighten to 35 lb-ft (47 N폷m). @
3.
Remove the fill plug from the side of the axle housing bowl
cover.
4.
Add the axle lubricant through the fill plug hole. Fill the axle
with the lubricant until the lubricant level is even with the
bottom of the fill plug hole.
5.
Install the fill plug. Tighten the plug to 35 lb-ft (47 N폷m)
minimum. When correctly installed, one complete thread of the
fill plug is visible between the housing and the plug head. @
10. Adjust the wheel bearings.
Oil-Lubricated Wheel Bearings
NOTE: If you cannot observe the oil level because the sightglass is
stained, remove the fill plug, check the oil level with your finger and
follow the procedures for Step 3 below. Replace the stained
sightglass as soon as possible.
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving.
2.
Check the oil level on the cap.
3.
If the oil level is more than 0.25-inch (6 mm) below the
specified level on the cap, remove the fill plug.
4.
Add the specified oil to the specified level. Figure 2.28.
5.
Install the fill plug.
앫 If the axle shafts or hubs are equipped with oil fill
plugs: Rotate the hub until the fill plugs are at the top.
Remove the oil fill plugs. Fill each hub cavity with 2 pints
(1 L) of rear axle lubricant. Install and tighten the fill plugs to
10 lb-ft (13.8 N폷m) minimum. @
앫 If the axle shafts and hubs are not equipped with oil fill
plugs: Slowly drive each side of the vehicle over a 6-inch
(152.4 mm) raised surface so that the oil can flow out to
the hubs. Check the oil level in the housing and refill to the
bottom of the fill plug.
Figure 2.28
TYPICAL OIL-LUBRICATED WHEEL BEARINGS
6.
LUBE
1003338a
Figure 2.28
Rear Axles
Inspection
Inspect components during regularly scheduled maintenance
intervals to ensure correct operation and maximize the life of
the parts.
Inverted Portal Drive Axle
Inspect Magnets
Inspect and clean the magnets located on the drain plug of each
helical gear case and on the axle center housing drain plug.
앫 If excessive debris is found on a magnet: Inspect all
components for the source of the debris.
Drain and Replace the Oil
1.
14
Meritor Maintenance Manual 1 (Revised 08-06)
Road test the vehicle in an unloaded condition for 1-2 miles
(1.6-3.2 km) at speeds not more than 25 mph (40 km/h).
Recheck the lubricant levels and all of the fasteners. Adjust
as necessary.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. The axle lubricant capacity changes
when the drive pinion angle changes.
mm1.fm.book Page 15 Thursday, August 24, 2006 12:29 PM
2 Bus and Coach
2
2.
Place a drain pan under the axle. Remove and drain the oil from
the two drain plugs on the lower side of the helical gear housing
and the plug below the carrier in the center housing. Install the
drain plugs and tighten them to 35 lb-ft (47 N폷m). Figure 2.29.
@
Inverted Portal Drive Axle Wheel Ends
NOTE: If the axle shafts or hubs are equipped with oil fill plugs, fill
the wheel ends with oil using the following procedure.
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving.
2.
Use a jack to raise the vehicle so that the wheels to be serviced
are off the ground. Support the vehicle with safety stands.
3.
Rotate the hub until the fill plugs are at the top.
4.
Remove the oil fill plugs. Fill each hub cavity with 2 pints
(0.95 liters) of the recommended rear hub axle lubricant.
5.
Install and tighten the fill plugs to 10 lb-ft (14 N폷m). @
Figure 2.29
RIGHT-HAND
ADJUSTING NUT
LOCKING CAPSCREW
BREATHER
BEARING
SUPPORT
REACTION
CAPSCREW
OIL FILL AND
LEVEL PLUG
OIL FILL
PLUG
HELICAL
GEAR CASE
DRAIN PLUG
HELICAL
GEAR CASE
DRAIN PLUG
CENTER HOUSING
DRAIN PLUG,
NOT SHOWN
4000890a
Figure 2.29
3.
Remove the fill plug from the helical gear case that is closest to
the differential. Figure 2.29.
4.
Fill the helical gear case with approximately 1.6 gallons
(6 liters) of lubricant until the lubricant level is even with the
bottom of the fill hole. Install the fill plug. Tighten the plug to
35 lb-ft (47 N폷m). @
5.
Remove the fill plug from the side of the axle housing bowl
cover. Figure 2.29.
6.
Fill the axle housing with approximately 5 gallons (19 liters)
of lubricant until the lubricant is level with the bottom of the
fill hole.
7.
Wait five minutes. Add lubricant to the axle center housing until
the lubricant is level with the bottom of the fill hole. Repeat this
step until the oil level in the axle center housing does not drop.
8.
Install the fill plug. Tighten the plug to 35 lb-ft (47 N폷m). When
correctly installed, one complete thread of the fill plug is visible
between the housing and the plug head. @
9.
Road test the vehicle in an unloaded condition for 1-2 miles
(1.6-3.2 km) at speeds not more than 25 mph (40 km/h).
Recheck the lubricant levels and all of the fasteners.
Adjust as necessary.
Planetary Drive Axles
Inspect the Thrust Button, Thrust Screw and
Coupling
NOTE: As a preventive maintenance procedure, you must inspect
the internal components of the wheel ends every 24,000 miles
(39 000 km) or at every brake reline, whichever comes first.
NOTE: Thrust surfaces can wear a combined total of 0.08-inch
(2 mm) from their original position. If the wear is greater than
0.08-inch (2 mm), you must disassemble the wheel end and inspect
the internal parts for wear.
1.
Inspect the thrust button and thrust screw.
앫 If a groove or recess is worn into the thrust button face,
from contact with the thrust screw: Replace the thrust
button.
앫 If the slotted end of the thrust screw is worn or shows
signs of mushrooming or galling: Replace the thrust
screw.
NOTE: Slide the coupling back on the shaft for inspection. Do not
remove it.
2.
Inspect the coupling on the axle shaft for wear. The thickness
of a new coupling is 0.24-inch (6 mm), with an allowable
surface wear of 0.039-inch (1 mm) along any groove. Measure
the thickness of the coupling along the thinnest part of the
groove. If any measurement is 0.20-inch (5 mm) or less,
replace the coupling.
앫 If the coupling thickness is less than the limits above:
Replace the coupling.
Meritor Maintenance Manual 1 (Revised 08-06)
15
mm1.fm.book Page 16 Thursday, August 24, 2006 12:29 PM
2 Bus and Coach
3.
Inspect the thrust washer on the end of the spindle for wear or
damage, especially around the flange area.
Figure 2.30
앫 If the thrust washer is worn, grooved or shows signs of
galling: Replace the thrust washer.
Drain and Replace the Oil
NOTE: The RC-26-633 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 when filling. Fill to the bottom of
each fill plug hole, same as the axle horizontal center line.
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving.
2.
Use a jack to raise the vehicle so that the wheels to be serviced
are off the ground. Support the vehicle with safety stands.
3.
Remove the wheel nuts, and tire and rim assemblies from both
wheel ends.
4.
Rotate the wheel ends so the drain plug in the spider is at the
BOTTOM. Place a drain pan under the wheel ends. Remove the
plug and drain the lubricant from both wheel ends. Install the
plug and tighten it to 18-25 lb-ft (24-34 N폷m). @
5.
Place a drain pan under the axle housing. Remove the plug
from the bottom of the axle housing. Drain the lubricant from
the carrier center section. Install the plug.
6.
Fill the wheel ends and the carrier center section with a
multigrade API GL-5 gear oil approved under MIL-PRF-2105E
specification.
FILL PLUG FOR CARRIER
4002876a
Figure 2.30
Figure 2.31
Rotate plug so
oil level is
same as axle
horizontal
center line.
LEVEL PLUG
OIL LEVEL
(HORIZONTAL
CENTER LINE)
4002877a
Figure 2.31
Figure 2.32
FILL HOLE
앫 The carrier fill plug is located in the axle housing bowl.
Figure 2.30.
앫 Original design wheel ends: Rotate the wheel ends so the
fill plug gives a level the same as the axle horizontal center
line. Figure 2.31.
앫 Revised design wheel ends: Rotate the wheel end until
the fill hole is at the TOP. Remove the oil level capscrew and
copper washer located in the center of the thrust screw.
Do not remove the thrust screw and lock nut. Fill until oil
comes out of the level hole in the center of the wheel end.
Install the copper washer and oil level capscrew. Tighten
the capscrew to 8 lb-ft (11 N폷m). Figure 2.32. @
16
Meritor Maintenance Manual 1 (Revised 08-06)
FILL PLUG
LEVEL
CONTROL
HOLE
OIL LEVEL
Do not touch
thrust screw
and nut.
LEVEL
CONTROL
SCREW
4002878a
Figure 2.32
mm1.fm.book Page 17 Thursday, August 24, 2006 12:29 PM
2 Bus and Coach
2
Cam Brakes
Figure 2.34
CAST PLUS™ BRAKE LUBRICATION AREAS
WARNING
CAMSHAFT
— SPLINES:
Apply lubricant directly.
During lubrication procedures, if grease flows from the seal
near the camshaft head, replace the seal. Remove all grease
or oil from the camshaft head, rollers and brake linings.
Always replace linings contaminated with grease or oil, which
can increase stopping distances. Serious personal injury and
damage to components can result.
SHOE ROLLERS —
Lubricate where
pins touch brake shoes.
— BUSHING:
Apply lubricant through
grease fitting.
For lubrication information, refer to Table M and Figure 2.33,
Figure 2.34 or Figure 2.35.
Figure 2.33
Q AND Q-PLUS™ BRAKE LUBRICATION AREAS
ANCHOR PINS —
Lubricate where
pins touch
brake shoes.
CAMSHAFT
— SPLINES:
Apply lubricant
directly.
ANCHOR PINS —
Lubricate grease
fittings in anchor
pins.
— BUSHING:
Apply lubricant
through
grease fitting.
4001493c
Figure 2.34
Figure 2.35
W SERIES BRAKE LUBRICATION AREAS
ANCHOR PINS —
Apply lubricant
through
grease fitting.
SHOE ROLLERS —
Lubricate where
pins touch
brake shoes.
4001492c
Figure 2.33
CAMSHAFT
— SPLINES:
Apply lubricant directly.
— BUSHING: Apply lubricant
through grease fitting.
SHOE ROLLERS —
Lubricate where pins
touch brake shoes.
4001494c
Figure 2.35
Meritor Maintenance Manual 1 (Revised 08-06)
17
mm1.fm.book Page 18 Thursday, August 24, 2006 12:29 PM
2 Bus and Coach
T Series Parking Brake
Anchor Pins
Camshaft Bushings
Lubricate the anchor pins when necessary or when the brake is
disassembled. Apply the lubricant to the anchor pins where the pins
touch the brake shoes. Figure 2.36.
WARNING
During lubrication procedures, if grease flows from the seal
near the camshaft head, replace the seal. Remove all grease
or oil from the camshaft head, rollers and brake linings.
Always replace linings contaminated with grease or oil, which
can increase stopping distances. Serious personal injury and
damage to components can result.
Lubricate the camshaft bushings initially at 30,000 miles
(48 280 km), then every 50,000 miles (80 467 km) or once a year,
whichever comes first. Lubricate the camshaft bushings through the
fittings in the differential carrier and the fitting in the drive pinion
bearing cage.
Camshaft Splines
Lubricate the camshaft splines when necessary or when the brake
is disassembled. Apply the lubricant to the camshaft splines.
Figure 2.36.
Lubricate the shoe rollers when necessary or when the brake is
disassembled. Apply the lubricant to the roller pins where the pins
touch the brake shoes. Do not apply lubricant on the part of the
roller that touches the cam head. Figure 2.36.
Stopmaster® Brakes
Lubricant Areas
Lubricate the following areas of the brake.
앫 The outer diameter, the ramp and the slot of the anchor plungers
앫 The outer diameter, the inner diameter, the ramp and the slot of
the adjusting plungers
앫 The teeth on the outer diameter and the threads on the inner
diameter of the actuators
앫 The teeth and the outer diameter of the adjusting pawls
Figure 2.36
T-SERIES PARKING BRAKE
CAMSHAFT
Lubricate splines
and bushings
through fittings
in carrier.
ANCHOR PINS
Lubricate where
pins touch
shoe assemblies.
SHOE ROLLERS
Lubricate where
rollers touch
shoe assemblies.
Figure 2.36
18
Shoe Rollers
Meritor Maintenance Manual 1 (Revised 08-06)
4001375c
앫 The rollers and the head of the wedge assemblies
앫 The plunger bores and the bore for the pawl in the plunger
housing
mm1.fm.book Page 19 Thursday, August 24, 2006 12:29 PM
2 Bus and Coach
2
Lubrication Intervals and Specifications
Table D: Front Non-Drive Axle Greasing
Component
Greasing Interval
Grease
King Pins and
Bushings
30,000 miles
(48 280 km) or
every preventive
maintenance interval,
whichever comes first
Multi-Purpose
Grease
Ball Studs on
Steering Arm,
Tie Rod Ends, and
Drag Link*
Meritor
Specification
NLGI
Grade
O-617-A
1
O-617-B
2
Outside
Temperature
Grease Type
Lithium 12
Hydroxystearate
or Lithium
Complex
Refer to the grease
manufacturer’s
specifications for
the temperature
service limits.
* Applies to ball studs on Easy Steer Plus™ axles. Sealed axles require inspection of the boot on the ball stud every 100,000 miles (160 000 km) for wear and
damage. Service as necessary.
Table E: Wheel-End Oil Change Intervals and Specifications
On-Highway Operation Intervals
Outside Temperature
°F
°C
Check Oil
Level
Petroleum Oil
Change
Meritor
Specifications
Military
Specification
Oil Description
Min.
Max.
Min.
Max.
1,000 miles
(1600 km)
Whichever comes
first:
O-76A Gear Oil
MIL-L-2105-D
GL-5, SAE 85W/140
10
None
12
None
O-76D Gear Oil
GL-5, SAE 80W/90
–15
None
–26
None
Seals replaced
O-76E Gear Oil
GL-5, SAE 75W/90
–40
None
–40
None
Brakes relined
O-76J Gear Oil
GL-5, SAE 75W
–40
36
–40
2
30,000 miles
(48 280 km)
Heavy-Duty Engine
Oil
MIL-L-2104-B,
-C, -D or -E
A.P.I. -CD, -CE, -SF
10
or -SG SAE 40 or 501
None
12
None
Twice a year
Heavy-Duty Engine
Oil
MIL-L-2104-B,
-C, -D or -E
A.P.I. -CD, -CE, -SG,
-SH or -SJ SAE 302
None
–26
None
1
2
–15
Current designations are acceptable. Multi-grade engine oils are acceptable if the SAE rating ends in 40 or 50.
Current designations are acceptable. Multi-grade engine oils are acceptable if the SAE rating ends in 30.
Meritor Maintenance Manual 1 (Revised 08-06)
19
mm1.fm.book Page 20 Thursday, August 24, 2006 12:29 PM
2 Bus and Coach
Table F: Rear Axle Lubricant Cross Reference (Viscosity and Temperature)
Meritor Lubricant
Specification
Description
Cross Reference
Minimum Outside
Temperature
Maximum Outside
Temperature
O-76-A
Hypoid Gear Oil
GL-5, SAE 85W/140
+10° F (–12° C)
*
O-76-B
Hypoid Gear Oil
GL-5, SAE 80W/140
–15° F (–26° C)
*
O-76-D
Hypoid Gear Oil
GL-5, SAE 80W/90
–15° F (–26° C)
*
O-76-E
Hypoid Gear Oil
GL-5, SAE 75W/80
–40° F (–40° C)
*
O-76-J
Hypoid Gear Oil
GL-5, SAE 75W
–40° F (–40° C)
+35° F (+2° C)
O-76-L
Hypoid Gear Oil
GL-5, SAE 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 G: Wheel-End Axle Greasing Intervals and Specifications
Greasing Interval
Whichever comes first:
Replacing seals
Meritor
Grease
NLGI
Specification
Multi-purpose
grease
O-617-A
(preferred) or
O-617-B
(acceptable)
Relining brakes
30,000 miles (50 000 km)
Table H: Rear Axle Lubricant Schedule
Type of
Service
Check Oil
Level
Oil Change Interval
Bus and
Coach
Every
3,000 miles
(4828 km)
Less than 60,000 miles
(96 558 km) a year: Change
two times per year
City Service
More than 60,000 miles
(96 558 km) a year: Change
every 25,000-30,000 miles
(40 233-48 279 km)
Coach
Highway
Operation
(Inter-city)
Every
3,000 miles
(4828 km)
Petroleum-based oil*
Initial drop at 1,000 miles
(1609 km)
100,000 miles (160 930 km) or
once per year, whichever is first
Synthetic-based oil*
No initial drop required
Change every 250,000 miles
(402 325 km)
* Do not use synthetic-base oil for RC-26-633, RC-26-720 and
RC-27-720 Series axles.
20
Meritor Maintenance Manual 1 (Revised 08-06)
Grease Grade
1 or 2
Outside
Classification
Lithium
12-Hydroxy
Stearate or Lithium
Complex
Temperature
Refer to the grease
manufacturer’s
specifications for
the temperature
service limits.
mm1.fm.book Page 21 Thursday, August 24, 2006 12:29 PM
2 Bus and Coach
2
Table I: Lubricant Capacities
Table J: Planetary Drive Axle Intervals
Axle Model
U.S. Pints*
Liters*
Initial Oil Change
Oil Change
59722
30.5
14.4
2,500 miles (4023 km)
25,000 miles (40 233 km)
59723
30.5
14.4
59732
30.5
14.4
59733
30.5
14.4
59752
30.5
14.4
59753
30.5
14.4
59842
30.5
14.4
59843
30.5
14.4
61042
41.0
19.4
61043
41.0
19.4
61052
41.0
19.4
61053
41.0
19.4
61063
44.0
20.8
61142
41.0
19.4
61143
41.0
19.4
61152
41.0
19.4
61153
41.0
19.4
61163
44.0
20.8
71063
44.0
20.8
71163
44.0
20.8
RC-23-160
41.0
19.4
RC-26-633
35.5
16.8
RC-26-720
52-56.8
24.6-26.9
RC-27-720
52-56.8
24.6-26.9
Table K: Planetary Drive Axle Lubricant Capacities
Carrier Center Section
Each Wheel End
35.5 pints (16.7 liters)
7.0 pints (3.3 liters)
* These quantities are approximate. Fill the housing with oil up to the
bottom of the oil fill hole in the housing cover. If the wheel ends have been
disassembled, oil must be provided to the wheel ends before the vehicle
is placed back into service.
Table L: Planetary Drive Axle Specifications
Outside Temperature
A.P.I. Specification
SAE Grade
Meritor Specification
Minimum
Maximum
GL-5
80W/90
O-76D
–15° F (−26° C)
None
GL-5
75W/90
O-76E
–40° F (−40° C)
None
Meritor Maintenance Manual 1 (Revised 08-06)
21
mm1.fm.book Page 22 Thursday, August 24, 2006 12:29 PM
2 Bus and Coach
WARNING
During lubrication procedures, if grease flows from the seal near the camshaft head, replace the seal. Remove all grease or oil from
the camshaft head, rollers and brake linings. Always replace linings contaminated with grease or oil, which can increase stopping
distances. Serious personal injury and damage to components can result.
For lubrication information, refer to Table M and Figure 2.33, Figure 2.34 or Figure 2.35.
Table M: Cam Brake Lubrication Intervals and Specifications
Brake
Component
Camshaft
Bushings
Specification
Multi-Purpose Chassis Grease, 6% 12-hydroxy
lithium stearate grease, NLGI Grade 1, Meritor
specification O-617-A or equivalent
Multi-Purpose Chassis Grease, 8% 12-hydroxy
lithium stearate grease, NLGI Grade 2, Meritor
specification O-617-B or equivalent
Brake Spider
(Wedge
Brakes Only)
Camshaft
Splines
Anchor Pins
Shoe Rollers
ArvinMeritor
Automatic
Slack
Adjusters*
Multi-Purpose Chassis Grease, 6% 12-hydroxy
lithium stearate grease, NLGI Grade 1, Meritor
specification O-617-A or equivalent
Multi-Purpose Chassis Grease, 8% 12-hydroxy
lithium stearate grease, NLGI Grade 2, Meritor
specification O-617-B or equivalent
Metallic-base, temperature resistant anti-seize
compound, Meritor specification O-637 or
equivalent
Anchor pin grease, non-melting grease with
Bentone thickeners, NLGI Grade 1, Meritor
specification O-616-A, O-617-B or equivalent
Multi-Purpose Chassis Grease, 6% 12-hydroxy
lithium stearate grease, NLGI Grade 1, Meritor
specification O-617-A or equivalent
Multi-Purpose Chassis Grease, 8% 12-hydroxy
lithium stearate grease, NLGI Grade 2, Meritor
specification O-617-B or equivalent
Clay-base, non-melting grease with Bentone
thickeners, NLGI Grade 1, Meritor specification
O-616-A or equivalent
Schedule
Lubricate at initial 30,000 miles
(48 280 km). Thereafter, lubricate every
50,000 miles (80 467 km) or once a
year, whichever comes first.
Procedure
Through the fitting on the
bracket or spider until new
grease flows from the
inboard seal.
For severe duty, lubricate more often.
Frequency is determined by monitoring
the condition of the grease.
When necessary or when the brake is
disassembled.
To areas that touch the
brake shoes.
When necessary or when the brake is
disassembled.
To all areas.
When necessary or when the brake is
disassembled.
Through the fitting where
the pins touch the brake
shoes.
To roller pins at areas
where the pins touch the
brake shoes. Do not apply
lubricant onto the part of
the roller that touches the
cam head.
When necessary or when the brake is
disassembled.
Whichever of the following is most
frequent:
앫 Every 6 months
Lithium-base, NLGI Grade 1 or 2, Meritor
specification O-692 or equivalent
앫 Four times during the life of the
linings
Synthetic oil, clay-base, NLGI Grade 2, Meritor
specification O-645 or equivalent
Always inspect and lubricate the
automatic slack adjuster when the
brakes are relined.
Through the fitting until
new grease purges from
around the inboard
camshaft splines and from
the pawl assembly.
* For non-Meritor automatic slack adjusters, refer to the vehicle manufacturer’s instructions for maintenance intervals and specifications.
22
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 23 Thursday, August 24, 2006 12:29 PM
2 Bus and Coach
2
Table N: T Series Parking Brake Lubricant Specifications
Description
Lubricant Specification
Camshaft
Bushings
Multi-purpose chassis grease, 6% 12-hydroxy
lithium stearate grease, NLGI Grade 1, Meritor
specification O-617-A or equivalent
Shoe
Rollers
Multi-purpose chassis grease, 8% 12-hydroxy
lithium stearate grease, NLGI Grade 2, Meritor
specification O-617-B or equivalent
Anchor Pin
Anchor pin grease, non-melting grease with
Bentone thickeners, NLGI Grade 2, Meritor
specification O-616 or equivalent
Camshaft
Splines
Metallic-base, temperature resistant anti-seize
compound, Meritor specification O-637 or
equivalent
Stopmaster® Wedge Brakes
Lubricate the Stopmaster® brake every six months or
100,000 miles (161 000 km).
The grease used in Meritor Stopmaster® brakes must be NLGI
Grade 1 or equivalent. The grease must keep its lubrication qualities
under high temperatures. The grease must be smooth and contain
no fillers or abrasives. The grease must have a resistance to water
and corrosion. The grease must remain soft under normal parking
storage conditions so that the brakes can be applied and released.
If the operating temperatures are down to –40° F (–40° C), use
the following lubricants or their equivalent.
앫 Special Brake Grease, Meritor specification O-616-A
앫 Texaco Thermotex EP 1
앫 Texaco Hytherm EP 1
앫 Shell Darina 1
앫 Aral Aralub 3837
If the operating temperatures go below –40° F (–40° C), use the
following lubricants or their equivalent.
앫 Special Low Temperature Brake Grease, Meritor
specification O-645
앫 Mobilgrease 28
앫 Mobilgrease 32
Meritor Maintenance Manual 1 (Revised 08-06)
23
mm1.fm.book Page 24 Thursday, August 24, 2006 12:29 PM
3 Clutches
Hazard Alert Messages
3 Clutches
Figure 3.2
15-1/2" MANUAL ADJUST CLUTCH
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
4001206a
Technical Publications
Figure 3.2
How to Obtain Additional Maintenance and
Service Information
Figure 3.3
14" DUAL-PLATE MANUAL ADJUST CLUTCH
Refer to the publications in Table O. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
Table O: Publications
Model
Manual
Clutches
Maintenance Manual 25A
Clutch Failure Analysis
TP-9494
4001207a
Figure 3.3
Description
Meritor clutches are primarily used on Class 6 to Class 8 series
vehicles. The clutches are available in 14-inch manual adjust,
15-1/2-inch manual adjust and 15-1/2-inch AutoJust™ models.
The clutches are available in an eight-hole installation pattern.
Figure 3.1, Figure 3.2 and Figure 3.3.
Figure 3.1
15-1/2" AUTOJUSTTM CLUTCH
4001205a
Figure 3.1
24
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 25 Thursday, August 24, 2006 12:29 PM
3 Clutches
Identification
To identify a clutch, refer to the identification and serial numbers
located on the front of the clutch cover. Refer to these numbers when
you replace parts. Use only the specified parts.
3
앫 For clutch models manufactured on or before May 1999:
Refer to the identification tag and serial number tag attached to
the clutch cover. Figure 3.4.
앫 For clutch models manufactured on or after May 1999:
Refer to the identification and serial numbers etched on the
clutch housing. Figure 3.5.
Figure 3.4
Figure 3.5
CO.
M E R I TO R C L U T C H
28
S P E C HC14C2200N
00
R E P L . N O . R1401
FOR
A DJUST
SERIAL
NUMBER
TAG
PS
53NT
0022051CH CE R
P
0 4151R L / S
27 5 4 9 4 N
IDENTIFICATION
TAG
4001209b
4001208c
Figure 3.4 Figure 3.4
Figure 3.5 Figure 3.5
Model Nomenclature
Refer to Figure 3.6 for an explanation of the original clutch
specification number. Refer to Figure 3.7 for an explanation of the
replacement clutch assembly part number.
Figure 3.6
H
C
15
M
200
Number
of Discs
1
2
Cover
C — Cast
S — Stamped
Series
H — Heavy Duty
M — Medium Duty
2
Size
14 — 14"
15 — 15-1/2"
N
N
36
Brake Option
B — Clutch Brake
N — No Brake
Spline
Size
200 — 2"
Facing Type
TM
A — LTD AutoJust (4-Paddle) (Ceramic)*
C — Ceramic
J — LTD AutoJustTM (6-Paddle) (Ceramic)*
K — LTD (6-Paddle) (Ceramic)*
L — Standard LTD prior to 6/98, Lite Pedal
LTD 6/98 and later (Ceramic)*
M — Molded (Organic)
P — LTD Lite Pedal prior to 6/98 (Ceramic)*
*Requires special flywheel damper opening of 10-1/8".
Clamp Load —
Pounds
28 — 2800
32 — 3200
36 — 3600
40 — 4000
Options
D — Hi Hysteresis/DD-S50 (Greaseable)
E — Greaseable Bearing (Free Travel LTD)
F — Dual Grease (Free Travel LTD)
G — Sealed Bearing (Free Travel LTD)
H — 600 HP/Hi Torque Engine (Greaseable)
N — Greaseable Bearing and Co-Axial
S — Sealed Extended Lube Bearing
T — Two-Stage (Greaseable)
U — 600 HP/Hi Torque Engine (Dual Grease Fitting for Mack)
W — 600 HP/Hi Torque Engine (Sealed Ext. Lube)
X — Two Stage (Sealed Extended Lube)
Y — Hi Hysteresis/DD-S50 (Sealed Extended Lube)
Z — Dual Grease Housing (Mack LTD)
4001311a
Figure 3.6
Meritor Maintenance Manual 1 (Revised 08-06)
25
mm1.fm.book Page 26 Thursday, August 24, 2006 12:29 PM
3 Clutches
Figure 3.7
R
15
1
Meritor
Designation
4
0
6
Clutch Type
0 — 8 Spring Standard or 7 Spring Standard LTD
1 — 14" 8 Spring Lite Pedal
5 — “Super 8” 8 Spring or 7 Spring LTD Lite Pedal*
6 — “Super 8” 8 Spring Lite Pedal or LTD 6-Paddle*
8 — AutojustTM (4-Paddle)*
9 — AutojustTM (6-Paddle)*
Unique
Identification
Number
Size
14 — 14"
15 — 15-1/2"
Facing Type
0 — Ceramic Disc
2 — Flat Flywheel (No longer available)/Dual grease fitting
3 — Hi Torque Dual Grease Fitting
5 — Molded Organic Disc (except Hi Torque LTD clutches which are ceramic)
Options
1 — 8 Spring Single-Stage Dampened Disc
4 — 8 Spring Two-Stage Dampened Disc
5 — Single Plate
6 — Standard LTD 7 Spring Dampened Disc (available as ceramic disc only)*
7 — Lite Pedal LTD 7 Spring Dampened Disc (available as ceramic disc only)*
8 — Two-Stage (Free Travel LTD) (available as ceramic disc only)*
All orders should refer to the replacement part number.
* Requires special flywheel damper opening of 10-1/8".
4001312a
Figure 3.7
Inspection
1.
When to Inspect the Clutch
Inspect the clutch when any of the following occurs.
앫 If the release fork does not move when the clutch
pedal moves: Find and service the cause of the free play
condition.
앫 As required by the maintenance schedule of the vehicle
manufacturer
앫 When any part of the clutch system is serviced
앫 When the clutch pedal free travel is less than 1/2-inch (13 mm)
or more than 1-1/2-inches (38 mm)
2.
Clutch Linkage
The clutch linkage must be inspected carefully. The clutch will not
operate correctly if the linkage is worn or damaged. Inspect the
linkage according to the following procedures. Figure 3.8.
3.
The condition of all parts of the linkage. Inspect the clutch
linkage. The pedal, springs, brackets, bushings, shafts, clevis
pins, levers, cables and rods must not be worn or damaged.
If a hydraulic system is used, verify that the system is not
leaking and that the reservoir is filled to the specified level.
Replace any parts that are missing or damaged. Do not
straighten any damaged parts.
4.
Lubrication. Every pivot point in the linkage must be
lubricated. Use the lubricant specified by the vehicle
manufacturer. Refer to the lubricant specifications listed in
this section.
CLUTCH
PEDAL
LINKAGE
4001296a
Figure 3.8
26
Meritor Maintenance Manual 1 (Revised 08-06)
The condition of the linkage operation. The linkage must
move if the pedal is actuated. The linkage must not be
obstructed. Every pivot point operates freely. The linkage must
not be loose at any point.
앫 If the linkage does not operate freely: Find and service
the cause of the condition.
Figure 3.8
RELEASE
FORK
The operation of the linkage. Push down on the clutch pedal
and have another person check the release fork for movement.
The smallest movement of the clutch pedal must cause
movement at the release fork.
mm1.fm.book Page 27 Thursday, August 24, 2006 12:29 PM
3 Clutches
Internal Parts of the Clutch
Remove the capscrews from the inspection cover. Remove the
cover. Inspect the internal parts of the clutch according to the
following procedure.
NOTE: A 1/2-inch gauge tool, SP2033, is available from Snap-on
Tools. Refer to the Table U.
Release Bearing Clearance. The AutoJust™ clutch
clearance should be 0.500-0.560-inch (12.7-14.2 mm).
Figure 3.10.
3.
Release Fork Clearance. Verify that there is a distance of
0.105-0.145-inch (2.67-3.68 mm) between the fork and the
boss of the release bearing. If the distance is not 1/8-inch
(3 mm), adjust the linkage. Figure 3.11.
CAUTION
The inspection cover on the clutch housing must be used. If an
inspection cover is not used, dirt and contaminants can get
into the clutch housing and damage the clutch.
1.
Release Bearing Clearance — Non-Synchronized
Transmission. Adjust the release bearing clearance if the
distance between the release bearing and the clutch brake is
not 0.500-0.560-inch (12.7-14.2 mm). Refer to Maintenance
Manual 25A, Clutches. To obtain this publication, refer to the
Service Notes page on the front inside cover of this manual.
Figure 3.9.
3
2.
NOTE: A 1/8-inch gauge tool, SP2034, is available from Snap-on
Tools. Refer to Table U.
Figure 3.9
RELEASE BEARING CLEARANCE — NON-SYNCHRONIZED TRANSMISSION
RELEASE
BEARING
0.500-0.560"
(12.7-14.2 MM)
CLEARANCE
1/2"
GAUGE
TOOL
CLUTCH
BRAKE
4001297a
Figure 3.9
Figure 3.10
0.500-0.560"
(12.7-14.2 MM)
CLEARANCE
CLUTCH
BRAKE
RELEASE
BEARING
1/2" TELESCOPING
GAUGE TOOL
4002689a
Figure 3.10
Meritor Maintenance Manual 1 (Revised 08-06)
27
mm1.fm.book Page 28 Thursday, August 24, 2006 12:29 PM
3 Clutches
Figure 3.11
1/8" (3 MM)
CLEARANCE
RELEASE FORK
1/8" GAUGE
TOOL
BOSS ON RELEASE BEARING
4002691a
Figure 3.11
4.
The AutoJust™ sensor bolt clearance between the bolt head
and flange should be 0.55-inch (14 mm) minimum.
5.
Release Fork Condition. Remove and replace the release fork
if the tips are worn or damaged.
6.
Release Bearing Condition. Replace the complete clutch
assembly if the bearing is worn or damaged. The bearing must
be lubricated.
7.
8.
Transmission Input Shaft Condition. If the splines are worn
or damaged, replace the input shaft.
Transmission Input Bearing Retainer. Inspect the input
bearing retainer on the transmission. Check the area where the
clutch brake touches the retainer. Replace it if worn.
5.
If the release bearing is equipped with a lube tube, grease
must be coming out of the bearing housing, which ensures that
lubricant is reaching the bearing. Verify that the lube tube is
secure and not damaged.
6.
Use the same procedure for extended lubrication clutches, at
the same specified interval.
7.
Install the inspection cover. Figure 3.12.
Figure 3.12
RELEASE BEARING LUBRICATION POINTS
Lubrication
Release Bearing
CAUTION
The inspection cover on the clutch housing must be used. If an
inspection cover is not used, dirt and contaminants will enter
the clutch housing and damage the clutch.
1.
Remove the inspection cover on the clutch housing.
2.
Clean all grease fittings prior to lubrication.
3.
Correctly lubricate the release bearing. Apply grease to the
grease fitting on the release bearing until a small amount of
grease comes out of the bearing housing. Do not overgrease.
4.
Apply grease to the release fork tips where they contact the
bearing housing. Also apply grease to the exposed
transmission input shaft between the clutch bearing housing
and the transmission input bearing retainer to lubricate the
clutch release sleeve bushing.
28
Meritor Maintenance Manual 1 (Revised 08-06)
GREASE
FITTING
Figure 3.12
1003314a
mm1.fm.book Page 29 Thursday, August 24, 2006 12:29 PM
3 Clutches
Clutch Housing
Linkage
1.
Clean all grease fittings prior to lubrication.
2.
Grease the release fork cross shaft by applying grease to each
fitting on the clutch housing until a small amount of grease
purges out. Use the specified lubricant at the recommended
interval. Refer to the lubricant specifications and maintenance
intervals of the vehicle manufacturer. Figure 3.13.
Figure 3.13
CLUTCH HOUSING GREASE
FITTINGS — BOTH SIDES
NOTE: Some vehicle manufacturers may use “lubed-for-life” ball
joints in the clutch linkage. Refer to the vehicle manufacturer’s
instructions.
3
Lubricate each pivot point on the linkage according to the vehicle
manufacturer’s procedure. Use the specified lubricant at the
recommended interval. Refer to the lubricant specifications and
maintenance intervals in the tables in this section. Figure 3.14.
Figure 3.14
Lubricate every pivot point
in the clutch linkage.
LUBRICATE
LUBRICATE
1003315a
Figure 3.13
1003316a
Figure 3.14
Lubrication Intervals and Specifications
Table P: Greasing Intervals and Specifications
Meritor
Specification
NLGI Grade
High
Temperature
Multi-Purpose
Wheel Bearing
Grease
O-661
1
2
1
2
Component
Greasing Interval
Grease
Standard
Greaseable
Release
Bearing
Approximately
15,000 miles
(24 140 km) or at
each engine oil
change
Extended
Lube Release
Bearing
Approximately
100,000 miles
(16 934 km)
Cross Shaft
Clutch
Linkage
1
2
Grease
Description
Outside
Temperature
3
Lithium
Complex
Down to –40° F
(–40° C)
—
—
—
—
—
—
—
—
Use the interval specified by the vehicle manufacturer or the fleet, but verify that the release bearing is greased once per month.
Use the grease specified by the vehicle manufacturer.
Meritor Maintenance Manual 1 (Revised 08-06)
29
mm1.fm.book Page 30 Thursday, August 24, 2006 12:29 PM
3 Clutches
Table Q: Approved Lubricants
Lubricant
Recommendation
Clutch Bearing Grease
Exxon Unirex N Grade 3 (NLGI
Grade 3, Lithium Complex)
Troubleshooting
Before troubleshooting the clutch, verify the following. Once these conditions are verified,
refer to Table R, Table S and Table T to troubleshoot the clutch.
1.
The engine is operating correctly.
2.
The engine mounts are in good condition.
3.
The driveline angles of the engine, transmission, driveshaft and rear axle are correct.
4.
The inspection cover is installed on the clutch housing.
Operating Conditions
Table R: Operating Conditions Diagnostic Table
Condition
Possible Cause
Correction
Clutch does not
release or does
not release
completely.
Release bearing clearance needs adjustment.
Adjust release bearing clearance.
Clutch linkage needs adjustment.
Adjust clutch linkage.
Worn or damaged linkage.
Lubricate linkage. Verify that the linkage is not loose.
If condition still exists, replace linkage.
Worn or damaged release bearing.
Lubricate release bearing. If condition still exists, replace
release bearing.
Worn or damaged splines on input shaft.
Replace input shaft.
Bell housing loose.
Tighten fasteners to specified torque. If necessary, replace
fasteners.
Center plate binding.
14-inch clutch: Inspect drive pins in flywheel housing and
slots in center plate. 15-1/2-inch clutch: Inspect tabs on
center plate and slots in cover. Service as necessary.
Damaged hub in clutch discs.
Replace discs.
Damaged pilot bearing.
Replace pilot bearing.
Excessively worn contact pads on release bearing.
Replace clutch assembly. Verify that the clutch is correctly
adjusted.
Tight or stiff pivots in clutch linkage.
Lubricate linkage. If condition still exists, replace linkage.
Worn or damaged clutch components.
Replace clutch assembly.
Worn or damaged pedal shaft or cross shaft
bushings.
Repair or replace as necessary.
Clutch pedal is
hard to operate.
30
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 31 Thursday, August 24, 2006 12:29 PM
3 Clutches
Table R: Operating Conditions Diagnostic Table
Condition
Possible Cause
Clutch slips out of
engagement.
Driver keeps foot on clutch pedal.
Use correct vehicle operating procedure.
Clutch release bearing clearance needs adjustment.
Adjust release bearing clearance.
Clutch linkage needs adjustment.
Adjust clutch linkage.
Worn or damaged clutch components.
Replace clutch assembly.
Worn or damaged facings.
Replace clutch discs.
Oil or grease on facings.
Replace clutch assembly.
Worn or damaged flywheel.
Service flywheel as necessary. Refer to the procedure of
engine or vehicle manufacturer.
Clutch has inadequate torque capacity.
Replace with clutch rated for maximum engine torque.
Linkage worn/excessive clearances.
Replace worn components.
Worn or damaged release bearing.
Lubricate release bearing. If condition still exists, replace
clutch assembly.
Bell housing loose.
Tighten fasteners to specified torque. If necessary, replace
fasteners.
Transmission neutral idle rattle.
Verify correct clutch is being used.
Damaged hub or broken co-axial springs in clutch
discs.
Replace clutch assembly.
Facings damaged.
Replace clutch assembly.
Damaged pilot bearing.
Replace pilot bearing.
Worn or damaged splines on input shaft.
Replace input shaft.
Clutch/flywheel out-of-balance.
Remove, check balance, or try reorienting clutch to flywheel.
If condition still exists, replace clutch assembly.
Worn or damaged splines in hub of clutch discs.
Replace clutch assembly.
Loose flywheel.
Tighten fasteners to specified torque. If necessary, replace
fasteners. Check flywheel mounting surface for damage,
replace if necessary.
Transmission-to-engine misalignment.
Check runout of flywheel and bell housing. Verify that the
transmission-to-engine alignment is correct. Refer to vehicle
manufacturer’s procedure.
Clutch is noisy.
Clutch vibrates.
Correction
Meritor Maintenance Manual 1 (Revised 08-06)
3
31
mm1.fm.book Page 32 Thursday, August 24, 2006 12:29 PM
3 Clutches
Components
Table S: Components Diagnostic Table
Condition
Broken tabs on
clutch brake
Worn or damaged
release bearing
housing
Worn bosses on
release bearing
housing
Worn or damaged
input shaft splines
Pressure plate
cracked or
damaged by heat
Adjusting ring
does not move
Warped hub in
clutch disc
Hub separates
from disc
Co-axial springs
separate from
disc
Heat damage on
disc
Linings separate
from discs
Cracked or
damaged center
plate
32
Possible Cause
Release bearing clearance needs adjustment.
Clutch linkage needs adjustment.
Driver engages clutch brake incorrectly while vehicle is
moving.
Driver keeps foot on clutch pedal.
Free travel not adjusted correctly.
Correction
Adjust release bearing clearance.
Adjust clutch linkage.
Use correct driving procedures.
Damaged or out-of-adjustment linkage.
Lubricate and adjust linkage. Inspect linkage for wear or
damage.
Lubricate shaft of release fork. If fork does not move freely,
replace shaft and fork assembly.
Adjust free travel to specification.
Verify that driveline angles are correct.
Install transmission correctly.
Replace clutch assembly.
Replace pilot bearing.
Use correct vehicle operating procedures.
Release fork binding.
Free travel out-of-adjustment.
Transmission not aligned.
Incorrect transmission installation procedures.
Damaged hubs in clutch discs.
Worn or damaged pilot bearing.
Driver engages clutch while vehicle is coasting to
create shock load.
Driver uses clutch as a brake to hold vehicle on a grade.
Free travel not adjusted correctly.
Oil or grease on facings.
Driver slips clutch excessively during engagement.
Too much dirt in bell housing.
Worn or damaged adjusting ring.
Incorrect transmission installation procedures.
Incorrect transmission installation procedures.
Clutch housing loose.
Use correct vehicle operating procedures.
Adjust free travel correctly.
Use correct vehicle operating procedures.
Adjust free travel to specification.
Replace clutch assembly.
Use correct vehicle operating procedures.
Remove dirt from bell housing. Service as necessary. Verify
that inspection cover is installed.
Replace clutch assembly.
Replace clutch assembly. Install transmission correctly.
Shock loading.
Shock loading.
Install transmission correctly.
Tighten clutch housing to specified torque. If necessary,
replace fasteners.
Use correct vehicle operating procedures.
Use correct vehicle operating procedures.
Driver keeps foot on clutch pedal or slips clutch.
Clutch does not engage or disengage completely.
Free travel not adjusted correctly.
Worn or damaged diaphragm spring.
Grease or oil on facings.
Facings worn past specified dimension.
Use correct vehicle operating procedures.
Refer to Table R.
Adjust free travel correctly.
Replace clutch assembly.
Replace clutch assembly.
Replace clutch assembly.
Driver does not start vehicle in correct gear.
Driver uses clutch as a brake to hold vehicle on a
grade.
Driver slips clutch excessively during engagement.
Use correct vehicle operating procedures.
Use correct vehicle operating procedures.
Meritor Maintenance Manual 1 (Revised 08-06)
Use correct vehicle operating procedures.
mm1.fm.book Page 33 Thursday, August 24, 2006 12:29 PM
3 Clutches
WARNING
Operate the vehicle according to the vehicle manufacturer’s
procedure. Do not coast downhill with the transmission in gear
and the clutch released. If the vehicle coasts downhill with the
transmission in gear and the clutch released, the facings can
separate from the disc and cause serious personal injury and
damage.
3
Table T: Driver Procedures Diagnostic Table
Driver Procedures
Results
Driver keeps foot on clutch pedal.
Clutch is always partially disengaged. Results in too much slipping and causes clutch to
overheat. Overheating causes damage to the linings, pressure plate, center plate and
flywheel. Release bearing is also damaged.
Driver uses clutch as a brake.
Promotes faster wear of linings on disc and causes clutch to overheat.
Driver shifts transmission before minimum shift
speed.
Places a severe shock on the drivetrain. Will damage disc hub assemblies.
Driver coasts downhill with the transmission in
gear and the clutch released.
Will place too many RPMs on input shaft due to rear axle driving transmission. Can
cause facings to separate from disc.
Driver applies clutch while coasting downhill.
Places a severe shock load on the drivetrain. Will damage disc and hub assemblies, as
well as the entire powertrain.
Driver applies clutch brake while shifting when
vehicle is moving.
Damages clutch brake. Damaged clutch brake results in gear clash or noise when
engaging first or reverse gears.
Special Tools
NOTE: To obtain these tools, refer to the Service Notes page on the front inside cover of this manual.
Table U: Special Maintenance Tools
Description
SPX Kent-Moore
Tool Number
Owatonna
Tool Number
Snap-on
Tool Number
Meritor
Tool Number
Clutch Adjustment Tool
J 36216
7028
GA454
R170000
Pedal Pusher
J 39610
—
—
—
1/2″ Gauge Tool (Non-Synchronized
Transmission)
—
—
SP2003
—
1/8″ Gauge Tool
—
—
SP2034
—
Meritor Maintenance Manual 1 (Revised 08-06)
33
mm1.fm.book Page 34 Thursday, August 24, 2006 12:29 PM
4 Drivelines
Hazard Alert Messages
Wing-Style Permalube™
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
The Meritor Wing-Style Permalube™ driveline requires lubrication
of the slip yoke splines only. Figure 4.2.
4 Drivelines
Figure 4.2
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Technical Publications
How to Obtain Additional Maintenance and
Service Information
Refer to the publications in Table V. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
Table V: Publications
Model
Manual
Drivelines
Maintenance Manual MM-96147
Driveline I.D. Gauge Kit
SP-87101B
Drivelines
Failure Analysis Manual TP-0445
WING-STYLE PERMALUBETM
4001790a
Figure 4.2
Full-Round, Easy Service™, Wing-Style and
155R Series (Greaseable)
Full-Round, Easy Service™, Wing-Style and 155R Series
greaseable drivelines require periodic lubrication of the universal
joints and slip yoke splines. Figure 4.3, Figure 4.4 and Figure 4.5.
Figure 4.3
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 lubricants. Arrows on the wing bushings help you to
correctly install the universal joint. Figure 4.1.
FULL-ROUND
4001788a
Figure 4.3
Figure 4.1
Figure 4.4
RPL SERIES PERMALUBETM
4001791a
Figure 4.1
34
Meritor Maintenance Manual 1 (Revised 08-06)
EASY SERVICETM (1/2 ROUND)
Figure 4.4
4001789a
mm1.fm.book Page 35 Thursday, August 24, 2006 12:29 PM
4 Drivelines
Inspection
Figure 4.5
Driveline
WARNING
155R SERIES
4001789b
Figure 4.5
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.
Only service a driveline when the engine is OFF. A rotating
driveline can cause serious personal injury.
Identification
Meritor genuine driveline components are identified by the following
markings on the component.
앫 Logo stamped on the part
앫 Balance bosses
앫 Forging part number which identifies the driveline series
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
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.
Table W: Drivelines
Meritor Driveline Series
155R
58WB
16N
62N
17N
72N
176N
82N
18N
85WB
25W*
92N
앫 If the output and input end yokes are loose: Disconnect
the driveline. Tighten the end yoke retaining nut to the
correct specification. Refer to the axle or transmission
manufacturer’s service instructions.
20W*
* RPL25 and RPL20 do not follow the above convention and utilize their
own unique numbering system.
4.
Inspect for worn universal joints. Apply vertical force of about
50 pounds (22.7 kg) to the driveline near the universal joints.
앫 If movement is greater than 0.006-inch (0.152 mm):
Replace the universal joint.
Meritor Maintenance Manual 1 (Revised 08-06)
35
4
mm1.fm.book Page 36 Thursday, August 24, 2006 12:29 PM
4 Drivelines
5.
Use a dial indicator to examine the slip yoke spline for
excessive radial movement. Radial movement between the slip
yoke and the tube shaft must not exceed 0.017-inches
(0.432 mm).
Figure 4.6
앫 If the radial movement exceeds 0.017-inch
(0.432 mm): Replace the slip yoke and the tube shaft.
6.
Inspect the driveline for damaged or bent tubing. Carefully
remove contaminants, such as mud and road debris.
End Yokes
Perform the following procedures before you lubricate universal
joints or slip yokes. If you lubricate these components before you
inspect them, lubricant can cover wear, damage and looseness.
1.
Figure 4.6
3.
Do not lubricate components. Inspect all input and output end
yoke retaining nuts and bolts for gaps between mating
surfaces.
앫 If gaps are present: Refer to the transmission, axle or
transfer case manufacturer’s service instructions.
2.
4001796a
Check the output and input end yokes on both the axle and
transmission for axial looseness using the following procedure.
Also refer to the axle or transmission manufacturer’s service
instructions.
WARNING
Use a fine-tooth file or an emery cloth to remove raised metal
or fretting from yoke 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.
A.
Hold the end yoke with both hands.
B.
Move the end yoke UP-AND-DOWN and SIDE-TO-SIDE.
There shouldn’t be any movement where the yoke
connects to the input and output shafts. Figure 4.6.
Inspect for worn, damaged, missing and loose parts. Replace
as required.
Inspect all end yoke cross hole surfaces and bolt hole threads
for damage. Remove raised metal or fretting with a fine-tooth
file or emery cloth. Figure 4.7.
앫 If bolt hole threads are damaged: Replace the yoke.
Figure 4.7
앫 If the input and output end yokes are loose:
Disconnect the driveline. Tighten the end yoke
retaining nut or bolt to the correct specification. Refer
to the axle or transmission manufacturer for correct
inspection and replacement procedures.
앫 If the input and output end yokes are not loose,
check that the transmission output shaft and axle
input shaft splines aren’t loose at the end yoke:
Hold the yoke with one hand and rotate it
LEFT-TO-RIGHT while you check end play for radial
looseness. Figure 4.6.
앫 If you find excessive radial looseness: Replace the
end yoke, or input or output shafts, as necessary.
36
Meritor Maintenance Manual 1 (Revised 08-06)
4001838a
Figure 4.7
mm1.fm.book Page 37 Thursday, August 24, 2006 12:29 PM
4 Drivelines
Universal Joints
Figure 4.9
WARNING
Excessive looseness across the ends of 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.
4
4001802a
1.
Use the following procedure to check for looseness across the
ends of the universal joint bearing cup assemblies and
trunnions.
A.
Hold the INBOARD yoke on the driveline with both hands.
B.
Try to move the yoke UP-AND-DOWN and SIDE-TO-SIDE
by applying at least 50 lb-ft (222.5 N폷m) of force to the
driveline near the universal joints. Figure 4.8. @
Figure 4.9
Center Bearings
1.
앫 If you can see gaps between the mating surfaces:
Disconnect the driveline. Tighten the coupling yoke
retaining nut to 450-600 lb-ft (612-816 N폷m). @
앫 If movement is greater than 0.006-inch
(0.152 mm): Replace the universal joint.
2.
Inspect all universal joint kits in the driveline assembly.
Inspect all center bearing and end yoke midship nuts for gaps
between the mating surfaces. Figure 4.10.
Figure 4.10
Figure 4.8
4001797a
Figure 4.10
4001794a
Figure 4.8
Greaseable Universal Joints
1.
Check that all grease fittings are installed. Replace missing
or damaged fittings. Tighten them to 6 lb-ft (8 N폷m).
Figure 4.9. @
2.
Check for loose grease fittings. Tighten them to 6 lb-ft
(8 N폷m). @
2.
Inspect the center bearing bracket bolts for looseness.
Figure 4.11.
앫 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.
Meritor Maintenance Manual 1 (Revised 08-06)
37
mm1.fm.book Page 38 Thursday, August 24, 2006 12:29 PM
4 Drivelines
Slip Yoke
Figure 4.11
NOTE: Check a slip yoke for movement with the driveline installed
and the vehicle on a level surface with its wheels on the ground.
1.
Check that the vehicle is on a level surface with its wheels on
the ground. The driveline should be installed.
2.
Firmly mount a dial indicator with a magnetic base onto the slip
yoke barrel next to the dust seal. Figure 4.13. You don’t 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 4.13.
4001880a
Figure 4.11
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.
Figure 4.13
앫 If any of these conditions are evident: Replace the
center bearing assembly.
NECK OF
SPLINE PLUG
SLIP YOKE
BARREL
DUST
SEAL
Self-Aligning Center Bearings
A self-aligning center bearing accepts ± 5 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.
3/4"
(19.05 MM)
MAXIMUM
Figure 4.13
4.
Some vehicles manufactured after January 18, 2002, are equipped
with self-aligning center bearings. Figure 4.12.
앫 If you replace a self-aligning center bearing on a vehicle
manufactured after January 18, 2002: You must install a new
self-aligning center bearing. Do not install an original-design
bearing.
4001871a
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 4.14.
앫 If movement exceeds 0.017-inch (0.432 mm):
Components are worn or damaged. Replace as required.
Figure 4.14
Figure 4.12
CENTER
BEARING
4001951a
Figure 4.12
38
Meritor Maintenance Manual 1 (Revised 08-06)
4001793a
Figure 4.14
mm1.fm.book Page 39 Thursday, August 24, 2006 12:29 PM
4 Drivelines
5.
Inspect the driveline for damage or bent tubing.
Wing-Style Permalube™ Drivelines
앫 If the driveline is damaged or bent: Replace the driveline.
1.
6.
If necessary, carefully remove mud or road debris from the
driveline.
7.
Inspect the slip yoke spline seal for grease leakage or seal
damage.
8.
Inspect for missing balance weights, damaged tubing or a
missing welch plug at the slip yoke.
앫 If the capscrews and lock washers are missing:
Check for damage to the universal joint and yoke.
Replace damaged parts and capscrews and lock washers.
앫 If the capscrews are loose: Remove and discard the loose
capscrews. Replace them with new capscrews and lock
washers.
Universal Joint Capscrews
WARNING
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:
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.
2.
Use a torque wrench to verify that capscrews are tightened to
the correct specification.
Check End Play
1.
앫 RPL Series Permalube™ drivelines: Install new capscrews
with Dri-Loc® patches.
Check the universal joint for end play. Apply force in an
UP-AND-DOWN and SIDE-TO-SIDE motion. The universal joint
must not move in either direction. 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.
앫 If movement is greater than 0.006-inch (0.152 mm):
Replace the universal joint.
앫 Wing-Style Permalube™ drivelines: Install new capscrews
with Dri-Loc® patches and secure the capscrews with lock
washers.
Figure 4.15
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).
RPL Series Permalube™ Driveline
1.
Check that capscrews are installed on all universal joint
positions. RPL Series Permalube™ capscrews and Wing-Style
Permalube™ capscrews are not interchangeable.
앫 If the capscrews are missing: Check for damage to the
universal joint and yoke. Replace damaged parts and
missing capscrews.
4001803a
Figure 4.15
Figure 4.16
앫 If the capscrews are loose: Remove and discard loose
capscrews. Replace them with new capscrews.
2.
Use a torque wrench to verify that capscrews are tightened to
115-135 lb-ft (155-183 N폷m). @
4001806a
Figure 4.16
Meritor Maintenance Manual 1 (Revised 08-06)
39
4
mm1.fm.book Page 40 Thursday, August 24, 2006 12:29 PM
4 Drivelines
CAUTION
A broken weld strap can cause a wing bushing to rotate. When
a bushing rotates, it’s possible to assemble it into the yoke
backward. To ensure correct assembly and prevent damage to
components, you must insert both of the wing bushing’s
machined keyways into the yoke.
2.
2.
Clean all grease fittings prior to lubrication.
3.
Apply the specified grease at the grease fitting on the universal
joint. Apply grease until new grease purges from all four seals.
앫 If new grease does not purge at all the seals: Loosen
the problem bearing cap bolts and regrease until all four
cups purge.
Replace the universal joint if it’s loose or the weld strap is
broken or missing.
Lubrication
RPL Series Permalube™ Driveline Universal
Joint, Slip Yoke and Splines
The universal joint, slip yoke and splines are permanently lubricated
and sealed and do not require regular lubrication. Figure 4.17.
앫 If new grease still does not purge: Replace the
universal joint.
Standard/Conventional Driveline Slip Yoke
and Splines
1.
Check the driveline for looseness. If loose, service the driveline
as necessary. Figure 4.18.
2.
Cover the vent hole in the welch plug with a finger.
3.
Apply the specified grease at the grease fitting on the slip yoke
until the grease purges from the deflector. Six to eight pumps
or approximately one ounce (28 grams) is sufficient to lube
the splines.
Figure 4.17
RPL SERIES PERMALUBETM
END
YOKE
CAPSCREWS
WELD
YOKE
SLIP YOKE
U-JOINT
CROSS
TUBING
1003318a
Figure 4.17
Wing-Style Permalube™ Driveline Universal
Joint
The universal joint is permanently lubricated and does not require
regular maintenance. Figure 4.19.
Figure 4.19
WING-STYLE PERMALUBETM
Standard/Conventional Driveline Universal
Joint
1.
Check the driveline for looseness. If loose, service the driveline
as necessary. Figure 4.18.
CAPSCREWS
SLIP
YOKE
COMBINATION FULL-ROUND/EASY SERVICETM
Figure 4.19
END
YOKE
SLIP YOKE
WELD YOKE
YOKE SADDLE
EASY SERVICETM
BEARING
CUPS
U-JOINT
CROSS
BEARING
STRAP
CAPSCREWS
Figure 4.18
40
Meritor Maintenance Manual 1 (Revised 08-06)
1003317a
WELD YOKE
GREASE TO
PURGE AT SEAL
U-JOINT
CROSS
Figure 4.18
FULL-ROUND
BEARING CUPS
END
YOKE
1003319a
mm1.fm.book Page 41 Thursday, August 24, 2006 12:29 PM
4 Drivelines
Wing-Style Greaseable Driveline Universal
Joint
Wing-Style Permalube™ and Greaseable
Driveline Slip Yoke and Splines
1.
Check the driveline for looseness. If loose, service the driveline
as necessary.
1.
Check the driveline for looseness. If loose, service the driveline
as necessary.
2.
Clean all grease fittings prior to lubrication.
2.
Clean all grease fittings prior to lubrication.
3.
Apply the specified grease at the grease fitting on the universal
joint. Apply grease until new grease purges from all four seals.
3.
Cover the vent hole in the welch plug.
앫 If new grease does not purge at all the seals: Loosen
the problem bearing cap bolts and regrease until all four
cups purge.
4.
Apply the specified grease at the grease fitting on the slip yoke
until grease purges from the deflector. Six to eight pumps or
approximately one ounce (28 grams) is sufficient to lube
the splines.
앫 If new grease still does not purge: Replace the
universal joint.
Intervals
Inspection and Maintenance
Table X: 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 (3200 km)
Verify that all bolts are tightened to 115-135 lb-ft (155-183 N폷m). @
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 leakage.
앫 If a universal joint shows normal grease leakage: Do not replace the universal joint.
앫 If a universal joint shows excessive grease leakage: Replace the universal joint.
2.
Check for excessive looseness across the ends of the universal joint bearing cup assemblies and trunnions.
앫 Grip the driveline near the INBOARD yoke with both hands.
앫 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 4.20.
Every 150,000 miles
(240 000 km)
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.
In addition to the 25,000-mile (40 000 km) requirements:
앫 Use a dial indicator to inspect the slip splines for wear (backlash). Radial looseness between the slip yoke and
the tube shaft must not exceed 0.017-inch (0.432 mm). Figure 4.21.
Meritor Maintenance Manual 1 (Revised 08-06)
41
4
mm1.fm.book Page 42 Thursday, August 24, 2006 12:29 PM
4 Drivelines
Table Y: Driveline Styles
Figure 4.20
Industry
Name/
Description
Standard or
Conventional
Driveline
Series
Type
16N
Full-Round
17N
Lubrication
Requirements
Splines and
Universal Joints
176N
18N
16T
4001795a
17T
Figure 4.20
176T
Easy
Service™
(1/2 Round)
Figure 4.21
18T
3/4"
(19.05 MM)
MAXIMUM
Figure 4.21
42
Meritor Maintenance Manual 1 (Revised 08-06)
4001870a
155R
1/2 Round
Wing-Style
Greaseable
92N
Wing-Style
Wing-Style
Permalube™
92N
Wing-Style
Splines Only
RPL Series
(Meritor
Permalube™)
RPL 25
Combination
Wing and
Full-Round
None
RPL 20
mm1.fm.book Page 43 Thursday, August 24, 2006 12:29 PM
4 Drivelines
Lubrication Intervals and Specifications
Table Z: Greasing Intervals and Specifications for Standard/Conventional Drivelines
Component
Application
Greasing Interval
Universal Joint, Line Haul — Applications 50,000 miles (80 000 km)
Slip Yoke and where tractor is operated
Splines
entirely on concrete or
smooth paved road
surfaces
Grease
Meritor
NLGI Grease
Specification Grade Description
Universal O-634-B
Joint
Grease
16,000 miles (25 000 km)
On Highway —
Applications where tractor
is operated at least 90%
on paved road surfaces
and up to 10% on gravel,
dirt or unpaved roads
2
Lithium
12-Hydroxy
Stearate with
Molybdenum
Disulfide
Outside
Temperature
Refer to the
grease
manufacturer’s
specifications
for the
temperature
service limits.
City — Applications
6,500 miles (10 000 km)
where truck is operated at
least 90% in city
environment
Construction — Straight
trucks used in the
construction industry to
move materials to and
from job sites. They
operate 90% on-road and
10% off-road with a high
number of stops and
starts
The greasing interval
depends on the individual
operating conditions, speed
and loads. To determine the
interval, inspect for the
presence of grease at all
positions until an interval
can be determined. Grease
the assembly as necessary.
Table AA: Approved Lubricants
Lubricant
Recommendation
Universal Joint
Grease
Must meet Meritor Specification O-634-B (NLGI Grade 2, Lithium 12-Hydroxy Stearate with Molybdenum Disulfide)
Amalie All Purpose Grease with Moly-L1-2M
Exxon 5160
Shell Super Duty Special FF
Marathon Maralube Molycode 529
Phillips Petroleum Philube MW-EP2 Grease
Shell Moly Poly Grease
Kendall L424 Grease
Amoco Super Chassis Grease
Ford Specification M1C-75B or part number PN-C1AZ 19590
Meritor Maintenance Manual 1 (Revised 08-06)
43
4
mm1.fm.book Page 44 Thursday, August 24, 2006 12:29 PM
4 Drivelines
Troubleshooting
WARNING
To prevent serious eye injury, always wear safe eye
protection when you perform vehicle maintenance or service.
Table AB: Vibration
Condition
Cause
Correction
Driveline vibration
Driveline phasing incorrect
Correct the phasing by aligning the yokes on both
ends of the driveline.
Missing balance weights or foreign material on
driveline tubing
Have the driveline balanced.
Transmission or axle end yokes loose
Inspect for radial looseness. Tighten the nut or replace
the end yoke.
Excessive end play in universal joints
Replace the universal joints.
Excessive hinging in slip section
Replace worn components.
Welch plug loose or missing in slip yoke
Replace the welch plug or slip yoke.
Worn center bearing
Replace the center bearing.
Chassis ride height too low or too high
Readjust the ride height.
Torsional accelerations in driveline
Measure the transmission, driveline and axle planes.
Record the readings and run the Driveline Analysis
Program.
If the angles are found to be out of specifications,
adjust or replace components as directed.
Low gear shudder at full
drive or full coast under
light load conditions
44
Incorrect phasing
Reassemble with correct phasing.
Driveline weight incompatible with
engine-transmission mounting
Install a two-piece driveline with a shaft support
bearing.
Driveline too long for speed
Install a two-piece driveline with a shaft support
bearing.
Loose outside diameter fit on slip yoke spline
Change the slip yoke and spline plug.
Universal joint loose
Inspect the universal joint for looseness; tighten to
specification. Replace if necessary.
Driveline out of balance or bent
Rebalance or replace.
Worn universal joint
Replace the universal joint.
Torsional or inertial excitation
Reduce the universal joint continuous running angle
by adding shims to driveline components.
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 45 Thursday, August 24, 2006 12:29 PM
4 Drivelines
Table AC: Premature Wear
Condition
Cause
Correction
Low mileage universal joint wear
End yoke cross hole misalignment
Use an alignment bar to check for end yoke cross
hole misalignment. Replace the end yoke if
misaligned.
Excess angularity
Check the universal joint operating angles.
Reduce the angles if necessary.
Incorrect lubrication
Lubricate according to specifications (non-RPL
designs).
Excessive continuous running load
Replace with a higher capacity universal joint and
driveline.
Continuous operation at high angle/high
speed
Replace with a higher capacity universal joint and
driveline. Check the universal joint operating
angles. Reduce the angles if necessary.
Worn or damaged seals
Replace the universal joint kit.
Excessive angularity
Check the universal joint operating angles.
Reduce the angles if necessary.
Excessive torque load for universal joint and
driveline size
Replace with a higher capacity universal joint and
driveline.
Excessive continuous running load
Replace with a higher capacity universal joint and
driveline.
Continuous operation at high angle/high
speed
Replace with a higher capacity universal joint and
driveline. Check the universal joint operating
angles. Reduce the angles if necessary.
Insufficient operating angles
Increase the operating angles to a minimum
of 2° .
Excessive torque load for universal joint and
driveline size
Replace with a higher capacity universal joint and
driveline.
Repeat universal joint wear
End galling of cross trunnion and
bearing assembly
TRUNNION
END
GALLING
4
4001860a
Needle rollers brinelled into bearing
cup and cross trunnion
UNIVERSAL
JOINT
TRUNNION
4001861a
Broken cross and bearing
assemblies
TYPICAL SHOCK
FAILURE —
CROSS DAMAGE
4001862a
Meritor Maintenance Manual 1 (Revised 08-06)
45
mm1.fm.book Page 46 Thursday, August 24, 2006 12:29 PM
4 Drivelines
Table AD: Slip Yoke Spline Wear
Condition
Cause
Correction
Seizure
Incorrect lubrication
Lubricate the slip yoke spline according to
specifications. Check the seal.
Worn or damaged part
Replace the spline components.
Contamination
Lubricate the slip yoke spline according to
specifications. Check the seal.
Worn or damaged parts
Replace the spline components.
Contamination
Lubricate the slip yoke spline according to
specifications. Check the seal.
Incorrect lubrication
Lubricate the slip yoke spline according to
specifications. Check the seal.
Excessive loose outside diameter fit
Replace the spline components.
Tube size inadequate
Use a larger diameter tube.
Excessive torque load for universal joints and
driveline size
Replace with a higher capacity universal
joint and driveline.
Condition
Cause
Correction
Shaft support bearing wear
Driveline too long for operating speeds
Install a two-piece driveline with a shaft
support bearing.
Incorrect lubrication of bearings
Replace the center bearing.
Bending fatigue due to secondary couple loads
Reduce the universal joint continuous
running angle.
Excessive torque load for universal joint and
driveline size
Replace with a higher capacity universal
joint and driveline.
Shaft support bearing misaligned; interferes with
deflector
Realign the mounting bracket to frame
crossmember to eliminate interference
with the deflector.
Balance weight located in apex of weld yoke lug
area
Replace the tubing and rebalance.
Balance weight too close to circle weld
Replace the tubing and rebalance.
Incorrect circle weld
Replace the tubing and rebalance.
Galling
Outside diameter wear at
extremities
Spline shaft or tube broken in
torsion
Table AE: Shaft and Tube
Shaft support rubber insulator wear
4001863a
Tube circle weld fracture
Table AF: Yoke Fracture
Condition
Cause
Correction
Yoke broken or cracked
Mating yoke lug interference at full jounce and
rebound
Replace the yoke. Check the design for
application. Use high angle yokes.
Excessive torque load for universal joint and
driveline size
Replace with a higher capacity universal joint and
driveline.
Bending fatigue due to secondary couple loads
Reduce the universal joint continuous running
angles.
4001864a
46
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 47 Thursday, August 24, 2006 12:29 PM
5 Front Drive Steer Axles
Hazard Alert Messages
Table AG: Publications
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
Model
Maintenance Manual
MX Series Medium-Duty
Front Drive Steer Axles
Maintenance Manual MM-0170
Heavy-Duty Front Drive
Steer Axles
Maintenance Manual 12
Single Reduction
Differential Carriers
Maintenance Manual 5
Front Drive Axles
Failure Analysis Manual TP-0445
5 Front Drive Steer Axles
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
Technical Publications
How to Obtain Additional Maintenance and
Service Information
Refer to the publications in Table AG. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
5
Description
Front Drive Steer Axles
Meritor produces a complete line of medium-duty and heavy-duty
front drive steer axles with single axle capacities of 10,000 lbs
(3732 kg) to 23,000 lbs (10 432 kg). Figure 5.1. Axle models are
available with:
앫 Single-reduction carriers
앫 Q Plus™ S-cam brakes
앫 Standard or wide track
앫 Driver-controlled main differential lock for increased traction
Figure 5.1
TYPICAL SINGLE-REDUCTION HEAVY-DUTY
FRONT DRIVE STEER AXLE
4000719a
Figure 5.1
Meritor Maintenance Manual 1 (Revised 08-06)
47
mm1.fm.book Page 48 Thursday, August 24, 2006 12:29 PM
5 Front Drive Steer Axles
Model Nomenclature
Current Models
MX-10-120
MX-19-145
MX-12-120
MX-21-160
MX-14-120
MX-23-160R
Front Drive Steer Axles
Front drive steer axle models are identified by a letter and number
system. The letters and numbers give important information about
the specific axle model.
MX-16-120
The first seven positions of the designations identify a basic axle
model. The second group of letters and numbers identify particular
specifications.
Prior Models
RF-16-145
RF-21-355
RF-21-155
RF-22-166
RF-21-156
RF-23-180
RF-21-160
RF-23-185
FDS-1600
FDS-2102
FDS-1805
FDS-2107
FDS-1807
FDS-2110
FDS-1808
FDS-2111
FDS-2100
FDS-2117
As an example, a 16,000 lb (7258 kg) front drive steer axle
with a single-reduction 120 model carrier is identified by the
following:
FDS-2101
Identification
The axle build information and assembly date for Meritor front drive
steer axles are on the axle identification tag. Figure 5.2.
Figure 5.2
MODEL AND
SPECIFICATION
NUMBER
CUSTOMER
NUMBER
MODEL MFS-12-143A-N
CUSTOMER NO 01X21A62
ASSY PLANT & SERIAL NO AVF 9521109
DATE 01327
AXLE
ASSEMBLY
DATE
TAG
EXAMPLE
AXLE ASSEMBLY
PLANT AND SERIAL
NUMBER
Figure 5.2
The identification tag is fastened to the axle housing.
48
Meritor Maintenance Manual 1 (Revised 08-06)
1000319f
mm1.fm.book Page 49 Thursday, August 24, 2006 12:29 PM
5 Front Drive Steer Axles
Figure 5.3
HSG Wall
0
1
2
3
4
5
6
7
8
9
GAWR
xx = GAWR (000) Pounds or Tonnes
(dependent on mfg. location)
Axle Model Type
S=
X=
D=
N=
P=
R=
T=
Z=
C=
H=
Single Rear (Solo)
Front Drive Steer
Fwd Rear w/IAD
Fwd Rear less IAD
Fwd Rear w/Pump
Rear Rear
Tandem Drive
Tridem Drive
Coach
High Entry
Relative Gearing
Size or Series
0
1
2
3
4
5
6
7
8
=
=
=
=
=
=
=
=
=
No Gearing
292/347
337/387
TBD
381/432
415/432
432/457
457
460/498
=
=
=
=
=
=
=
=
=
=
Cast
TBD
0.31 in.
0.37/0.39 in.
0.43 in.
0.50/0.51 in.
0.56 in.
TBD
0.63 in.
TBD
(8 mm)
(9.5/10.0 mm)
(11 mm)
(12.7/13.0 mm)
(14.3 mm)
(16 mm)
Carrier Variation
A=
D=
M=
N=
R=
Aluminum
Ductile
Ductile Rear, Amboid
No Carrier
Ductile Front Drive Axle
Carrier, Right Hand
T = Ductile Telma
5
Ratio 1
Ratio 2
M X - xx - 1 2 0 x N - x - N 1 2 3 - xxxx - xxxx
M = Meritor
Carrier Type
0
1
2
3
4
5
6
7
9
=
=
=
=
=
=
=
=
=
No Carrier
Single Speed
Two Speed
Helical Double Reduction
Salisbury
Planetary Double Reduction
Hub Reduction
Portal
Single Speed With
Torque Output
Limited Engine
MFG Location
N=
S=
E=
A=
North America
South America
Europe
Australia/Asia/Africa
Wheel End/Brake Attachment/Differential
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
Conventional Spindle/Conventional Brake/Standard Differential
Conventional Spindle/Conventional Brake/DCDL
Conventional Spindle/Conventional Brake/NoSPIN®
Conventional Spindle/Conventional Brake/Other Differential
Unitized Spindle/Conventional Brake/Standard Differential
Unitized Spindle/Conventional Brake/DCDL
Unitized Spindle/Conventional Brake/NoSPIN®
Unitized Spindle/Conventional Brake/Other Differential
Conventional Spindle/Integral Brake/Standard Differential
Conventional Spindle/Integral Brake/DCDL
Conventional Spindle/Integral Brake/NoSPIN®
Conventional Spindle/Integral Brake/Other Differential
Unitized Spindle/Integral Brake/Standard Differential
Unitized Spindle/Integral Brake/DCDL
Unitized Spindle/Integral Brake/NoSPIN®
Unitized Spindle/Integral Brake/Other Differential
Bolt on Conventional Spindle/Conventional Brake/No Differential
Specification Number
Includes: TRACK,
PARKING BRAKE, TELMA,
OTHER
Brake Type
B
C
D
E
F
G
H
K
L
N
P
Q
R
S
T
W
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
“B” Frame Brake
Air Disc Brake
Wedge Brake, Dual Air Chambers
Wedge Brake, Dual Hydraulic Cylinders
Wedge Brake, Single Hydraulic Cylinder
DuraPark Hydraulic Drum
Qualdraulic Disc
Disc PlusTM Air Disc
Q Plus Cam Brake
None
P Series Cam Brake
Q Series Cam Brake
Cast PlusTM Brake
Wedge Brake, Single Air Chamber
T Series Cam Brake
W Series Cam Brake
4002706a
Meritor Maintenance Manual 1 (Revised 08-06)
49
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5 Front Drive Steer Axles
Front Drive Steer Axles, Prior Models
Front drive steer axle models manufactured from 1989 to 2002 are
identified by a letter and number system. The letters and numbers
give important information about the specific axle model.
As an example, a 16,000 lb (7258 kg) front drive steer axle with a
single-reduction 145 model carrier is identified by the following:
The first seven positions of the designations identify a basic axle
model. The second group of letters and numbers identify particular
specifications.
Figure 5.4
Manufacturing Location
B — Brazil
E — Europe (CVC)
M — Europe (Maudslay)
N — U.S.A.
Nominal Axle Load Rating (GA WR)
in Thousands of Pounds
Gearing Type
1 — Single Speed
3 — Helical Double-Reduction
5 — Planetary Double-Reduction
6 — Hub Reduction
Meritor
(Rockwell)
RF 16 1 4 5 N F Q F* 123 614
Main Differential Nest Type
B — Special Differential
C — Driver -Controlled
Differential Lock
F — Standard Differential
H — High Traction Differential
N — NoSpin® Differential
Brake Type
B — Hydraulic Disc Brake
D — RDA Wedge Brake (Dual Air
Chambers)
E — RDH Wedge Brake (Dual Hydraulic
Cylinders)
F — RSH Wedge Brake (Single Hydraulic
Cylinder)
H — Hydraulic Drum Brake
L — Q PlusTM Cam Brake
N — None
Q — Q Series Cam Brake
S — Wedge Brake (Single Air Chamber)
Carrier Ratio
Axle Specification Number
Identifies specific customer configuration,
(variations from the original base axle
design). Refer to the Bill of Materials for
specification details.
Fr ont Drive
Steer Axle
Axle Design Variation
Indicates axle design level or
variation, (e.g. RF-21-156
indicates same base carrier as
RF-21-155 except 156 is right-hand
geared and 155 is left-hand
geared). Refer to Bill of Materials
for details.
Carrier Type
Carrier size. Larger numbers
indicate a higher GCW rated
carrier, i.e. larger ring gear,
etc.
Hub Type
A — Aluminum
C — Cast Spoke Wheel
F — Ferrous
N — None
*NOTE: This position will be used to
designate hub only until more than three
digits are required to designate axle
specification.
NOTE: If a complete axle designation is not
required, use the first seven positions of the
model designation to identify the basic axle
model.
EXAMPLES OF BASIC AXLE MODELS:
RF-23-180: Front Drive, 23,000 lb. (10,500 kg)
GAWR, Single Speed, 19.62 inch
(498 mm) Ring Gear, 180 Carrier
Model.
RF-21-355: Front Drive, 21,000 lb. (9,526 kg)
GAWR, Helical Double-Reduction,
11 inch (279 mm) Ring Gear, 355
Carrier Model (Formerly R-255).
4000716a
50
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 51 Thursday, August 24, 2006 12:29 PM
5 Front Drive Steer Axles
Meritor heavy-duty front drive steer axle models manufactured
before 1989 were identified as shown in Figure 5.3. For
example, an 18,000 lb (8165 kg) front drive steer axle with a
double-reduction 255 carrier model was identified as
FDS-1805-SAX-60 10.59.
Figure 5.3
FDS-1805-SAX-60 10.59
Meritor makes a complete line of FDS series front drive axles
with single axle capacities of 7,500 lb (3400 kg) to 23,000 lbs
(10 500 kg).
FDS series front drive axle model designations show the capacity,
carrier model and design modifications of each model. The letters
and numbers of the model designation correspond with information
listed in Table AH.
Carrier Ratio
Customer Specification
Number
5
Brake Type
Basic Capacity
Front Drive Steer Axle
4002692a
Figure 5.3
Table AH: Front Drive Steer Axle Model Specifications
Axle Model
Capacity, lb (kg)*
Carrier Model
Design Modification
FDS-75
7,500 (3400)
F-106
Standard
FDS-78
7,500 (3400)
F-106
Heavy-duty wheel ends
FDS-85
9,000 (4082)
H-140
Special carrier
FDS-90
9,000 (4082)
F-106
Standard
FDS-93
9,000 (4082)
F-106
Special track and offset bowl
FDS-1600
16,000 (7257)
H-140
Right-hand or left-hand gearing
FDS-1805
18,000-21,000 (8165-9525)
R-255
Double-reduction
FDS-1807
18,000-21,000 (8165-9525)
R-155
Single-reduction
FDS-1808
18,000-21,000 (8165-9525)
R-155
Right-hand gearing
FDS-2100
21,000 (9525)
R-155
Right-hand gearing
FDS-2101
21,000 (9525)
R-155
Left-hand gearing
FDS-2102
21,000-23,000 (9525-10 433)
R-255
Double-reduction
FDS-2107
23,000 (10 433)
R-170
Single-reduction
FDS-2110
21,000 (9525)
R-155
Wide track, right-hand gearing
FDS-2111
21,000 (9525)
R-155
Wide track, left-hand gearing
FDS-2112
21,000 (9525)
R-255
Wide track, double-reduction
FDS-2117
23,000 (10 433)
R-170
Wide track, single-reduction
* Capacities vary with application and service. All applications must be approved by the Meritor Engineering Department.
Meritor Maintenance Manual 1 (Revised 08-06)
51
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5 Front Drive Steer Axles
Inspection
Figure 5.4
DIAL
INDICATOR
Steering-Related Components
Fasteners
Verify that all fasteners are tightened to the specified torque. Use a
torque wrench to check the torque in a tightening direction. As soon
as the fastener starts to move, record the torque. Correct if
necessary. Replace any worn or damaged fasteners.
Wear and Damage
Inspect the parts of the axle for wear and damage. Look for bent or
cracked parts. Replace all worn or damaged parts.
4000069a
Figure 5.4
Pivot Points
Verify that looseness does not exist at the pivot points. Verify that
the pivot points are lubricated.
4.
Operation
For heavy-duty axles, the reading must be 0.005-0.015-inch
(0.127-0.381 mm). Figure 5.4.
Verify that all the parts move freely through the complete turning
radius.
앫 If the reading is not within specification: The axle
components are damaged and must be replaced.
Tire Wear
Inspect the tires for wear patterns that indicate suspension damage
or misalignment.
Steering Arm Bolts
Check torque every 200,000 miles (320 000 km).
Upper and Lower Knuckle Bushings
1.
Park the vehicle on a level surface. Place blocks under the
wheels not being serviced to prevent the vehicle from moving.
2.
Raise the vehicle so that the wheels to be serviced are off the
ground. Support the vehicle with safety stands.
3.
Check the upper king pin bushing for wear. Install the base of a
dial indicator onto the axle beam. Place the indicator tip against
the side of the knuckle top, curbside or against the king pin
cap, driver side. Figure 5.5.
4.
Set the dial indicator on ZERO.
Steering Knuckle Vertical End Play
1.
Park the vehicle on a level surface and block the wheels to
prevent the vehicle from moving.
2.
Use a jack to raise the vehicle until the front wheels are off the
ground. Support the front axle with safety stands.
3.
Install a dial indicator for each side of the axle beam.
A. Turn the wheels straight ahead.
B. Install the dial base on the axle beam.
C. Place the dial indicator tip onto the upper knuckle cap.
D. Place a jack and a wood block, with a hole that allows
clearance for the lower grease fitting, under the lower king
pin cap area. Figure 5.4.
E. Set the dial indicator on ZERO.
F. Raise the jack until you start to lift the axle beam off the
safety stands. Measure and record the dial indicator reading.
G. Lower the jack.
52
Meritor Maintenance Manual 1 (Revised 08-06)
For medium-duty axles, the reading must be
0.001-0.065-inch (0.025-1.650 mm) for new axles and
0.001-0.075-inch (0.025-1.905 mm) for axles in service.
mm1.fm.book Page 53 Thursday, August 24, 2006 12:29 PM
5 Front Drive Steer Axles
5.
Move the top of the tire side-to-side TOWARD and AWAY from
the vehicle.
Figure 5.6
앫 If the dial indicator moves a total of 0.010-inch
(0.254 mm): The upper bushing is worn or damaged.
Replace both bushings in the knuckle. Refer to the
appropriate maintenance manual for complete service
information. Figure 5.5.
Figure 5.5
FRONT VIEW CURBSIDE
5
DRIVER SIDE
1000008d
Figure 5.6
Tie Rod Ends
1000007d
Figure 5.5
6.
Check the lower king pin bushing. Install a dial indicator so that
the base is on the I-beam and the tip is against the side of the
bottom of the knuckle. Figure 5.6.
7.
Set the dial indicator on ZERO.
8.
Move the bottom of the tire side-to-side TOWARD and AWAY
from the vehicle.
1.
Park the vehicle on a level surface with the front wheels in the
straight-ahead position.
2.
Place blocks under the rear wheels to prevent the vehicle from
moving.
3.
Remove dirt and grease from the tie rod end seals.
4.
Place the dial indicator base on the bottom of the tie rod arm.
5.
Place the indicator tip near the tie rod end greasing fitting.
Figure 5.7. Set the dial indicator on ZERO.
앫 If the dial indicator moves a total of 0.010-inch
(0.254 mm): The lower bushing is worn or damaged.
Replace both bushings in the knuckle. Refer to the
appropriate maintenance manual for complete service
information. Figure 5.6.
Meritor Maintenance Manual 1 (Revised 08-06)
53
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5 Front Drive Steer Axles
Why It’s Important to Inspect the Tie Rod
Ends for Wear and Allowable Movement at
the Regularly-Scheduled Intervals
Figure 5.7
TIE ROD
END
UP
You may not be able to detect loose or worn tie rod ends during
operation. Under normal operating conditions, wear occurs over
time. The preload bearings inside each tie rod end provide less
resistance, which can affect steering control, front tire wear and
other axle components. Figure 5.8.
DOWN
1000326b
Regularly-scheduled inspection and maintenance helps to minimize
the effects of tie rod end wear on the vehicle. Figure 5.8.
Figure 5.7
Figure 5.8
CAUTION
BALL/STUD
Check the tie rod end play by hand. Do not use a pry bar which
can affect the accuracy of the dial indicator reading. Damage
to components can result.
6.
Move the tie rod end cross tube assembly UP and DOWN by
hand. Record the dial indicator reading.
앫 If the dial indicates a reading of more than 0.060-inch
(1.52 mm): Replace the tie rod end.
7.
NATURAL
PIVOT WEAR
Place the dial indicator on the tie rod end assembly at the
opposite side of the vehicle.
BALL/STUD
Servicing the Tie Rod Ends
When performing service and maintenance procedures, use a
service pit, if available. Otherwise, use one of the following
procedures.
Safety Stands
NOTE: Do not grease the tie rod assembly before you perform the
inspection.
1.
Park the vehicle on a level surface. Place blocks under the
wheels not being serviced to prevent the vehicle from moving.
2.
Raise the vehicle so that the area to be serviced is off the
ground. Support the vehicle with safety stands.
3.
Inspect and lubricate the tie rod ends.
Ramps
1.
Drive the vehicle onto ramps. Follow the ramp manufacturer’s
instructions.
2.
Inspect and lubricate the tie rod ends.
54
Meritor Maintenance Manual 1 (Revised 08-06)
NATURAL
BEARING
WEAR
SOLID
STEEL
BEARING
SURFACE
Figure 5.8
BALL/STUD
1003401d
mm1.fm.book Page 55 Thursday, August 24, 2006 12:29 PM
5 Front Drive Steer Axles
Tie Rod Assembly Movement
WARNING
NOTE: Do not grease the tie rod assembly before you perform the
inspection.
1.
Park the vehicle on a level surface. Place blocks under the rear
wheels to prevent the vehicle from moving.
2.
Raise the front end of the vehicle off the ground. Support the
vehicle with safety stands.
3.
Verify that a cotter pin is installed through the tie rod end, and
the tie rod end nut is tightened to the correct torque
specification. Replace a missing cotter pin and tighten a loose
tie rod end nut. A missing cotter pin or loose tie rod end nut
can cause loss of steering control. Serious personal injury and
damage to components can result.
6.
With the engine off, turn the wheels from full left to full right,
and then return to the straight-ahead position. This step will
require more force for vehicles with the power steering off.
Check that the tie rod end nut is installed and secured with a
cotter pin.
앫 If the cotter pin is missing: Check the nut torque
specification. Install a new cotter pin. Always tighten the tie
rod end nut to 300 lb-ft (407 N폷m) when installing the
cotter pin. Figure 5.10. @
NOTE: The boot may be missing completely or may not completely
cover the ball joint.
Figure 5.10
4.
Check that the boot is in place and completely installed over
the tie rod end.
5.
Check for cracking or tears in the boot. Also check the boot
seals for damage. Replace the entire tie rod if the boot is
damaged or missing. Figure 5.9.
Figure 5.9
Cracked or torn boot
requires entire tie rod
end replacement.
A missing cotter pin or a
loose tie rod end nut requires
immediate attention.
1003403b
Figure 5.10
1003402a
Figure 5.9
7.
Check that the tie rod end is threaded correctly into the cross
tube and installed deeper than the end of the cross tube slot.
The tie rod end must be visible the entire length of the cross
tube slot. Figure 5.11.
Meritor Maintenance Manual 1 (Revised 08-06)
55
5
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5 Front Drive Steer Axles
CAUTION
Figure 5.11
Tie rod end installed
deeper than the end
of the cross tube slot.
Only use your hands to check for movement or looseness of
the tie rod assembly. Do not use a crow bar, pickle fork or
two-by-four. Do not apply pressure or force to the tie rod
assembly ends or joints. Do not rock the tires with the vehicle
on the round or with the wheels raised. Damage to
components can result.
11. Use a push-pull movement to apply approximately 100 pounds
(45 kg) of hand pressure several times to the tie rod assembly.
Check for movement or looseness at both tie rod ends.
Figure 5.13.
TIE ROD CROSS
TUBE SLOT END
Tie rod threads must
be visible the entire
length of the cross tube slot.
앫 If there is movement or looseness in the tie rod
assembly: Replace both tie rod ends.
1003404a
Figure 5.11
Figure 5.13
8.
Check that the grease fittings are installed. Replace a damaged
grease fitting.
앫 If the tie rod ends are non-greaseable: Do not install a
grease fitting if the tie rod end is the non-greaseable type.
Figure 5.12.
Figure 5.12
ALTERNATE
GREASE
FITTING
LOCATIONS
Check movement by hand
by pushing and pulling.
1003406b
Figure 5.13
1003408a
Figure 5.12
9.
By hand or using a pipe wrench with jaw protectors to avoid
gouging the cross tube, rotate the cross tube toward the
FRONT of the vehicle and then toward the REAR.
앫 After rotating, center the cross tube.
앫 If the cross tube will not rotate in either direction:
Replace both tie rod ends.
10. Position yourself directly underneath the ball stud socket.
Grasp the end of the tie rod assembly with both hands as close
as possible to the socket. Your hands should be within
6-inches (152.4 mm) of the socket.
56
Meritor Maintenance Manual 1 (Revised 08-06)
CAUTION
Replace bent or damaged cross tubes with original equipment
parts of the same length, diameter and threads. Do not
attempt to straighten a bent cross tube. Damage to
components can result.
12. Inspect the cross tube and clamps for damage. Figure 5.14.
앫 If the cross tube is bent or cracked: Replace it. Use
original equipment parts of the same length, diameter and
threads.
앫 If the clamps are damaged: Replace them.
앫 If either clamp has become welded to the cross tube:
Replace the entire cross tube assembly. Use original
equipment parts of the same length, diameter and threads.
mm1.fm.book Page 57 Thursday, August 24, 2006 12:29 PM
5 Front Drive Steer Axles
Figure 5.14
CROSS TUBE
CLAMP
CRACK DAMAGE
NOTE: As the truck hub unit warms up during operation, some
small amounts of grease will purge out the outboard dust seal as
pressure is released from inside the truck hub unit. The grease
purge is permissible if it does not exceed two grams or about
one-half teaspoon. Do not replace the truck hub unit if the grease
purge does not exceed two grams.
3.
Remove the wheel and tire. Remove the hubcap.
4.
Attach the magnetic base of a dial indicator stand to the end of
the spindle. Touch the indicator stem against the face of the
wheel pilot of the truck hub unit.
5.
Set the dial indicator on ZERO.
1003407b
Figure 5.14
Steering Arm Bolts
WARNING
Take care when you use Loctite® adhesive to avoid serious
personal injury. Read the manufacturer’s instructions before
using this product. Follow the instructions carefully to prevent
irritation to the eyes and skin. If Loctite® adhesive material
gets into your eyes, follow the manufacturer’s emergency
procedures. Have your eyes checked by a physician as soon
as possible.
1.
Inspect the steering arm bolts. Verify that the torque is a
minimum of 300 lb-ft (406 N폷m). @
앫 If the steering arm bolt torque is below 300 lb-ft
(406 N폷m): Remove the bolts, clean all threads and
install new Loctite® 680 sealant, Meritor part number
2297-K-5523. Tighten the bolts to 300-450 lb-ft
(406-610 N폷m). @
2.
Check the steering arm bolt torque every 200,000 miles
(320 000 km) or 24 months, whichever comes first.
Sealed Hub Units
Inspect the truck hub unit end play every 200,000 miles
(320 000 km) or 24 months, whichever comes first.
5
NOTE: An end play reading of 0.0-inch is approved for the truck
hub unit. Don’t replace the unit if you obtain this reading.
6.
Slightly rotate the truck hub unit in both directions while
pushing INWARD until the dial indicator doesn’t change.
Repeat this step while pulling OUTWARD. The difference
between the two readings is the end play.
앫 If the end play is greater than 0.003-inch (0.076 mm):
Recheck the torque on the inner wheel bearing nut.
7.
Repeat Step 4. Record measurements greater than 0.003-inch
(0.076 mm) and less than 0.009-inch (0.229 mm) in a
maintenance log.
8.
Check that the truck hub unit rotates smoothly.
앫 If the end play reaches 0.009-inch (0.229 mm) or the
truck hub unit is very rough or noisy while rotating:
Replace the truck hub unit.
Carrier
Drive axles generate small metal wear particles at a fairly steady
rate, especially during the break-in period. If these fine, but hard
particles are allowed to circulate in the lubricant, along with external
moisture and dirt, the internal components will wear at a much
faster rate than normal.
NOTE: The truck hub unit is sealed and greased, and requires no
maintenance. Disassembly, lubrication or repair of the truck hub unit
will void the manufacturer’s warranty.
1.
Park the vehicle on a level surface. Place blocks under the
wheels not being serviced to prevent the vehicle from moving.
2.
Raise the vehicle so that the wheels to be serviced are off the
ground. Support the vehicle with safety stands.
Meritor Maintenance Manual 1 (Revised 08-06)
57
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5 Front Drive Steer Axles
Magnets and Magnetic Drain Plugs
Check and Adjust the Oil Level
Meritor front driving axles are equipped with magnetic drain plugs
that have a minimum pickup capacity of 1.5 lbs (0.7 kg) of low
carbon steel.
1.
Verify that the vehicle is parked on a level surface.
2.
Remove the fill plug from the axle.
The magnetic drain plug can be reused if, after cleaning, the plug has
a minimum pickup capacity of 1.5 lbs (0.7 kg) of low carbon steel.
3.
The oil level must be even with the bottom of the fill plug hole.
앫 If oil flows from the hole when the plug is loosened:
The oil level is high. Let the oil drain to the correct level.
NOTE: Inspect the magnetic drain plug each time the oil is changed.
Use the correct part. Pipe plugs will leak if used as a drain plug.
Breather
CAUTION
Cover the breather when steam cleaning the housing to
prevent water from entering the housing and contaminating
the oil. Damage to components can result.
Baffle-type breathers help keep the axles free from external
moisture and dirt, which can cause premature oil and component
failure.
앫 If the oil level is below the bottom of the fill plug hole:
Add the specified oil.
4.
Drain and Replace the Oil
1.
Verify that the vehicle is parked on a level surface. Place a
large container under the axle.
2.
Remove the drain plug from the bottom of the axle. Drain and
discard the oil correctly.
3.
Clean, install and tighten the drain plug to 35-50 Ib-ft
(48-67 N폷m). @
4.
Remove the fill plug from the axle.
5.
Fill the axle to the bottom of the fill plug hole with the specified
oil. Allow enough time for the oil to circulate through the axle
assembly.
6.
Install and tighten the fill plug to 35-50 Ib-ft (48-67 N폷m). @
Seals
CAUTION
Always use the correct tools and procedures when replacing
the seals to prevent incorrect installation and help prevent the
seals from leaking.
Seals keep the lubricant in and the dirt out of a component. When
they are worn or damaged, seals leak and produce low lubricant
levels which may damage components.
Durable triple-lip seals, standard in Meritor axles, protect the quality
and levels of the lubricant and provide superior performance.
Temperature Indicators
CAUTION
Meritor axles can operate above 190° F (88° C) without damage.
However, if the oil temperature reaches 250° F (121° C), stop
the vehicle immediately and check for the cause of
overheating. Damage to components can result.
Many Meritor axles have a tapped hole in the housing for the
installation of a lubricant temperature indicator that will help reduce
the failure of axle parts from overheated oil.
58
Meritor Maintenance Manual 1 (Revised 08-06)
Install and tighten the fill plug to 35-50 Ib-ft (48-67 N폷m). @
Lubrication
Knuckle King Pins
With the vehicle weight on the wheel end, pump grease through the
grease fittings located on the upper cap or steering arm and lower
cap assemblies. Grease should purge through the seals and thrust
bearing.
mm1.fm.book Page 59 Thursday, August 24, 2006 12:29 PM
5 Front Drive Steer Axles
Camshaft Retainer Bushing and Cam Bushing
2.
Pump grease until it purges through the seals. Figure 5.15.
Apply the specified grease at the grease fitting on the cross
tube until new grease purges from all the seals.
앫 If new grease does not purge at the seals: Move the
cross tube while applying grease at the fittings until new
grease purges from all the seals.
Figure 5.15
앫 If new grease still does not purge: Disassemble the
cross tube. Inspect the grease and the components.
Service as necessary.
GREASE
PURGE
LOCATIONS
Drive Axle Shaft Universal Joints
GREASE
FITTINGS
1.
Permanently-lubricated Permalube™ joints do not have a
grease fitting provided. Periodic greasing is not required for
these parts. For serviceable universal joints with grease
fittings, follow Step 2 and Step 3.
2.
Clean all grease fittings prior to lubrication.
3.
Apply the specified grease at the grease fitting on the universal
joint. Apply grease until new grease purges from all the seals.
GREASE
FITTINGS
5
앫 If new grease does not purge at every seal: Move the
driveline while applying grease at the fittings until new
grease purges at every seal.
GREASE
PURGE
LOCATIONS
앫 If new grease still does not purge: Disassemble the
universal joint. Inspect the grease and the components.
Service as necessary.
4000066a
Figure 5.15
Axle Shaft Spline and Thrust Washer
Cross Tube End Assembly
1.
Check the cross tube for looseness of more than 0.060-inch
(1.52 mm). Figure 5.16.
On axles with greaseable drive flanges, pump grease through the
grease fitting until it purges at the axle shaft seal. Figure 5.17.
Figure 5.17
앫 If the cross tube is loose: Service as necessary.
GREASE
FITTING
Figure 5.16
KNUCKLE BUSHING
GREASE FITTING
SEAL
1005432b
Figure 5.17
CROSS TUBE
GREASE FITTING
4000067b
Figure 5.16
Meritor Maintenance Manual 1 (Revised 08-06)
59
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5 Front Drive Steer Axles
Knuckle Bushing
6.
Install new wheel seals into the hubs.
1.
Check the knuckle for looseness. The correct end play is
0.001-0.065-inch (0.025-1.65 mm) for new axles or
0.001-0.075-inch (0.025-1.9 mm) for in-service axles.
If loose, service as necessary.
7.
Install the hub and the wheel and tire assembly. Install the
outer wheel bearing cone into the hub. Install the adjusting nut.
8.
Adjust the wheel bearings.
2.
Clean all grease fittings prior to lubrication.
Tie Rod End
3.
Apply the specified grease at the grease fitting on the knuckle.
Apply grease until new grease purges from all the seals.
Grease the lower pin cap with the vehicle weight on the wheel
end to ensure that the thrust bearing is completely greased.
1.
Turn the vehicle wheels straight ahead. Figure 5.18.
Figure 5.18
앫 If new grease does not purge at the seals: Move the
knuckle while applying grease at the fittings until new
grease purges at the seals.
앫 If new grease still does not purge: Disassemble the
knuckle. Inspect the grease and the components. Service
as necessary.
Wheel Bearings
Point wheels straight ahead.
WARNING
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
1.
Park the vehicle on a level surface. Place blocks under the
wheels not being serviced to prevent the vehicle from moving.
2.
Raise the vehicle so that the wheels to be serviced are off the
ground. Support the vehicle with safety stands.
3.
Use the correct cleaning solvent to remove the old grease from
all parts. Discard the seals. Inspect the wheel bearings for
wear or damage. Replace worn or damaged bearings.
4.
Use a pressure packer to force the specified grease from the
large end of the cones into the cavities between the rollers and
cage. Pack the hub between the bearing cups with grease to
the level of the smallest diameter of the cups.
앫 If a pressure packer is not available: Grease the
bearings by hand.
5.
60
Install the inner and outer bearing cones into the cups in the
hubs. The bearing cups must be pressed tight against the
shoulder in the hubs.
Meritor Maintenance Manual 1 (Revised 08-06)
1003405a
Figure 5.18
2.
Wipe the grease fitting and seal and boot, with shop towels.
3.
Attach either a hand or air pressure grease gun to the grease
fitting. Old grease should purge from the holes near the boot
crimp or bellows area, usually at three or more places.
Figure 5.19.
앫 If using air pressure: Do not exceed 150 psi (1035 kPa).
mm1.fm.book Page 61 Thursday, August 24, 2006 12:29 PM
5 Front Drive Steer Axles
4.
Figure 5.19
SLIDING SEAL TIE
ROD ENDS
TRW — LUBE PURGES
EVENLY FROM BASE OF BOOT
NON-REMOVABLE AND ALL-WEATHER
BOOT SEAL TIE ROD ENDS
5.
If the tie rod end is designed for lube service and does not
accept grease, perform the following procedure.
A.
Remove the grease fitting.
B.
Inspect the threaded grease fitting hole in the tie rod end
and remove any obstructions.
C.
Install a new grease fitting.
D.
Continue the lubrication procedure.
Apply grease until all the old grease is purged from the boot.
Steering Knuckle Sockets
O & S — LUBE
PURGES FROM THREE
HOLES TOP OF BOOT
TRW — LUBE
PURGES FROM
BOOT BASE IN EVEN,
SMALL STREAMS
1.
Verify that the tires touch the ground. Do not raise the vehicle.
2.
Clean the grease fitting prior to lubrication.
3.
Lube the knuckle sockets through the grease fittings on the top
and bottom knuckle caps. Figure 5.20.
Figure 5.20
UPPER
GREASE
FITTING
URRESKO — LUBE PURGES
FROM TOP OF BOOT
O & S — LUBE
PURGES FROM THREE
HOLES TOP OF BOOT
LOWER
GREASE
FITTING
4000068a
Figure 5.20
O & S — NON-GREASEABLE
4.
1003424c
Force lubricant into the upper and lower knuckle sockets until
the lubricant flows out between the axle housing sockets and
the steering knuckle.
Figure 5.19
Meritor Maintenance Manual 1 (Revised 08-06)
61
5
mm1.fm.book Page 62 Thursday, August 24, 2006 12:29 PM
5 Front Drive Steer Axles
Lubrication Intervals and Specifications
Table AI: Front Drive Steer Axle Oil Change Intervals and Specifications
Initial Oil Change
No longer required as of January 1, 1993
Check Oil Level
Every 5,000 miles (8000 km), once a month, or the fleet maintenance interval, whichever comes first*
Petroleum Oil
Change
Every 25,000 miles (40 000 km) or annually, whichever comes first
Synthetic Oil
Change
Every 50,000 miles (80 000 km) or annually, whichever comes first
* 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.
Table AJ: Front Drive Steer Axle Component Greasing Intervals
Meritor
Specification
Component
Greasing Intervals
Grease
Cross Tube End
Assemblies and
Knuckle Bushings
3,000 miles (4800
km) or 200 hours of
operation, whichever
comes first
Multi-Purpose O-617-A or
Grease
O-617-B
U-Joint
Grease
U-Joints
O-634-B
NLGI
Grade
Grease Classification
Outside Temperature
1 or 2
Lithium 12-Hydroxy Stearate
or Lithium Complex
2
Lithium 12-Hydroxy
Stearate with Molybdenum
Disulfide
Refer to the grease
manufacturer’s
specifications for the
temperature service
limits.
Table AK: Wheel-End Axle Greasing Intervals
Greasing Intervals
Whichever comes first:
앫 Replacing seals
Grease
Multi-Purpose
Grease
앫 Relining brakes
앫 On-highway:
30,000 miles (48 000 km)
Meritor
Specification
O-617-A
(preferred) or
O-617-B
(acceptable)
NLGI
Grade
1 or 2
Grease Classification
Lithium 12-Hydroxy
Stearate or Lithium
Complex
Outside Temperature
Refer to the grease
manufacturer’s specifications for
the temperature service limits.
앫 On/off highway and
off-highway: Twice a year
Table AL: Lubricant Specifications
Meritor
Specification
Oil
Oil Description
O-76A
Gear Oil
GL-5, SAE 85W/140
O-76D
Gear Oil
GL-5, SAE 80W/90
O-76E
Gear Oil
GL-5, SAE 75W/90
O-76J
Gear Oil
GL-5, SAE 75W
O-76L
Gear Oil
GL-5, SAE 75W/140
O-76M
Full-Synthetic Oil
GL-5, SAE 75W/140
O-76N
Full-Synthetic Oil
GL-5, SAE 75W/90
Military Specification Approval for all oils is ML-L-2105D or MIL-PRF-2105-E.
62
Meritor Maintenance Manual 1 (Revised 08-06)
Outside Temperature
°F
Min.
Max.
10
None
–15
None
–40
None
–40
35
–40
None
–40
None
–40
None
°C
Min.
–12
–26
–40
–40
–40
–40
–40
Max.
None
None
None
2
None
None
None
mm1.fm.book Page 63 Thursday, August 24, 2006 12:29 PM
5 Front Drive Steer Axles
NOTE: Axle lube oil capacity is 2 gallons (7.5 liters).
Table AM: Front Drive Steer Axle Oil Capacities by Model
Axle Model
FDS-75
FDS-2101
RF-7-120
FDS-78
FDS-2102
RF-9-106
FDS-85
FDS-2107
RF-9-120
FDS-90
FDS-2110
RF-12-120
FDS-93
FDS-2111
RF-12-125
FDS-750
FDS-2117
RF-16-145
Oil Capacity*
Pints
13.0
28.0
15.0
13.0
43.0
14.0
13.0
43.0
15.0
13.0
43.0
15.0
13.0
43.0
15.3
13.9
43.0
36.4
Liters
6.2
13.2
7.0
6.2
20.3
6.6
6.2
20.3
7.0
6.2
20.3
7.0
6.2
20.3
7.2
6.5
20.3
17.2
Axle Model
FDS-1600
MX-10-120
RF-21-155
FDS-1800
MX-12-120
RF-21-156
FDS-1805
MX-14-120
RF-21-160
FDS-1807
MX-16-120
RF-21-355
FDS-1808
MX-23-160
RF-22-166
FDS-2100
RF-7-106
RF-23-180
Oil Capacity*
Pints
21.0
20.0
27.9
28.0
20.0
27.9
28.0
20.0
43.7
28.0
20.0
28.0
28.0
43.0
43.0
28.0
14.0
39.3
Liters
9.9
9.0
13.2
13.2
9.0
13.2
13.2
9.0
20.7
13.2
9.0
13.2
13.2
20.0
20.0
13.2
6.6
18.6
5
* Oil capacities are for standard track axles that have been measured at various common drive pinion angles. The quantities listed include enough oil for both
wheel ends. These oil capacities will change if the track or the drive pinion angle is different.
Troubleshooting
Table AN: Front Drive Steer Axle Troubleshooting
Condition
Cause
Correction
Tires wear out quickly or
have uneven tire tread
wear.
Tires have incorrect air pressure
Adjust the air pressure in the tires.
Tires out-of-balance
Balance or replace the tires.
Incorrect tandem axle alignment
Align the tandem axles.
Incorrect toe-in setting
Adjust the toe-in specified setting.
Incorrect steering arm geometry
Service the steering system as necessary.
Excessive wheel end play
Readjust the wheel bearings.
Power steering system pressure low
Repair the power steering system.
Steering gear linkage not assembled correctly
Assemble the steering gear correctly.
Steering linkage needs lubrication
Lubricate the steering linkage.
King pins binding
Replace the king pins.
Vehicle is hard to steer.
Incorrect steering arm geometry
Service the steering system as necessary.
Caster out-of-adjustment
Adjust the caster as necessary.
Tie rod ends hard to move
Replace the tie rod ends.
Worn thrust bearing
Replace the thrust bearing.
Meritor Maintenance Manual 1 (Revised 08-06)
63
mm1.fm.book Page 64 Thursday, August 24, 2006 12:29 PM
5 Front Drive Steer Axles
Table AN: Front Drive Steer Axle Troubleshooting
Condition
Cause
Correction
Tie rod ends are worn and
require replacement.
Tie rod ends require lubrication
Lubricate the cross tube ends. Verify that the lubrication
schedule is followed.
Severe operating conditions
Increase the frequency of the inspection and lubrication
intervals.
Damaged boot on the tie rod end
Replace the boot.
Too much pressure in the power steering
system; pressure exceeds vehicle
manufacturer’s specification
Adjust the power steering system to the specified
pressure.
Power steering system cut-off pressure,
out-of-adjustment
Adjust the power steering system to the specified
pressure.
Vehicle operated under severe conditions
Verify that the vehicle is operated correctly.
Add-on type of power steering system not
installed correctly
Correctly install the add-on power steering system.
Steering gear overtravel poppets incorrectly set
or malfunctioning
Check for correct operation or adjust the overtravel of
the poppets to the vehicle manufacturer’s
specifications.
Axle stops incorrectly set
Set the axle stops to the vehicle manufacturer’s
specification.
Drag link fasteners tightened higher than the
vehicle manufacturer’s specifications
Tighten the drag link fasteners to the specified torque.
Lack of lubrication or incorrect lubricant
Lubricate the linkage with the specified lubricant.
Power steering stops out-of-adjustment
Adjust the stops to the specified dimension.
Worn or missing seals and gaskets
Replace the seals and gaskets.
Incorrect lubricant
Lubricate the axle with the specified lubricant.
Axle not lubricated at scheduled intervals
Lubricate the axle at the scheduled intervals.
Incorrect lubrication procedures
Use the correct lubrication procedures.
Lubrication schedule does not match operating
conditions
Change the lubrication schedule to match the operating
conditions.
Bent or broken cross tube,
tie rod end ball stud,
steering arm or tie rod end.
Component requires
replacement.
Worn or broken steering
ball stud
Worn king pins and king
pin bushings
Vibration or shimmy of
front axle during operation
64
Caster out-of-adjustment
Adjust the caster.
Wheels or tires out-of-balance
Balance or replace the wheels and tires.
Worn shock absorbers
Replace the shock absorbers.
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 65 Thursday, August 24, 2006 12:29 PM
6 Front Non-Drive Steer Axles
Hazard Alert Messages
6 Front Non-Drive Steer Axles
Figure 6.1
DRIVER SIDE
Read and observe all Warning and Caution hazard alert messages
in this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
STEERING
ARM
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
CURBSIDE
KNUCKLE
TIE
ROD
TIE ARM
ROD
TIE ROD CROSS
END
TUBE ASSEMBLY
CONVENTIONAL NON-DRIVE STEER AXLE
How to Obtain Additional Maintenance and
Service Information
1000318c
Figure 6.1
6
Figure 6.2
Refer to the publications in Table AO. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
DRIVER SIDE
Table AO: Publications
Model
Manual
Front Non-Drive Steer Axles
Maintenance Manual 2
STEERING
ARM
CURBSIDE
KNUCKLE
Description
The descriptions and procedures contained in this maintenance
manual are applicable to all Meritor front non-drive steer axles.
Meritor front non-drive steer axles are available in conventional,
Easy Steer Plus™ and MFS designs. Axle steering components
include steering arm, tie rod cross tube assembly, tie rod arm, tie
rod end and knuckle. Figure 6.1 and Figure 6.2.
TIE
ROD
END
TIE
ROD
ARM
TIE
ROD
EASY STEER PLUSTM MFS WITH UNITIZED WHEEL END
1000001e
Figure 6.2
Meritor Maintenance Manual 1 (Revised 08-06)
65
mm1.fm.book Page 66 Thursday, August 24, 2006 12:29 PM
6 Front Non-Drive Steer Axles
Identification
Figure 6.3
VIEW OF AXLE BEAM
FACING VEHICLE
The axle build information and assembly date for Meritor front
non-drive steer axles are on the axle identification tag. Figure 6.3.
The identification tag is fastened to the center of the beam at the
front surface. The axle assembly date is located in either the lower
right-hand or left-hand corner of the tag.
MODEL AND
SPECIFICATION
NUMBER
The Julian method is used to indicate the axle assembly date and is
shown in Figure 6.3. The first two digits indicate the year, and the
last three digits indicate the day of the year.
CUSTOMER
NUMBER
MODEL MFS-12-143A-N
CUSTOMER NO 01X21A62
In the following example, 01 is the year 2001 and 327 refers to
November 22.
ASSY PLANT & SERIAL NO AVF 9521109
DATE 01327
To identify the model number, refer to the identification plate on the
front of the beam. Use the complete model number to order parts.
AXLE
ASSEMBLY
DATE
TAG
EXAMPLE
AXLE ASSEMBLY
PLANT AND
SERIAL NUMBER
1000319d
Figure 6.3
Model Nomenclature
Refer to Figure 6.4 for an explanation of non-MFS front non-drive model numbers. For an explanation of MFS model numbers,
refer to Figure 6.5.
Figure 6.4
Meritor Identification
Front Axle
Basic Capacity
A 5,000 lbs
B 6,000 lbs
C 7,000-8,000 lbs
D 9,000 lbs
E 10,000 lbs.
F
12,000-13,200 lbs
G 14,600 lbs
L
16,000-20,000 lbs
LX 30,000 lbs
U 28,000-30,000 lbs
Basic Series
Brake Usage
Specification Number
F F - 9 8 1 - L X - 122
Major Variation
0 Pre-FMVSS-121 Design
1 Straight Sealed King Pin and New Tie
Rod Assembly
2 Sealed King Pin Construction
3 Larger Axle Beam and Knuckles
4 Easy Steer™ Design
5 Tubular Axle Beam
6 Lightweight Axle Beam
7 Center-Point™ Design
8 Easy Steer Plus™
Number Design Variation
0 Tapered King Pin
1 Straight King Pin
2 Special Tie Rods
3 5" Drop from Center of Spindle to Pad
4 5" Drop from Center of Spindle
to Pad and Special Tie Rods
5 Special Wheel Ends
6 Double Drop Beam
1000003d
Figure 6.4
66
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 67 Thursday, August 24, 2006 12:29 PM
6 Front Non-Drive Steer Axles
Figure 6.5
KPI
(inches)
13 =
16 =
21 =
22 =
24 =
33 =
43 =
44 =
51 =
Drop
(inches)
68.0
68.0
69.0
69.0
69.0
71.0
71.5
71.5
72.0
3.74
3.60
3.30
3.50
5.00
3.74
3.74
5.00
3.30
KPI
(inches)
53 =
62 =
63 =
75 =
85 =
86 =
92 =
94 =
72.0
65.24
65.25
60.0
67.5
67.5
68.5
68.5
Drop
(inches)
3.74
3.74
3.74
2.50
2.50
3.60
3.50
5.00
Major Design Variation
A = Conventional Knuckle
B = Integral Tie Rod Arm
C = Integral Tie Rod Arm and
Torque Plate
D = Integral Tie Rod Arm, Spider
and 65 mm Unitized Hub
F = Conventional Knuckle,
58 mm Unitized Spindle
M F S - XX - 0 0 0 X - N X XXX
Manufacturing
Location
N
S
E
A
=
=
=
=
N.A.
S.A.
Europe
Australia/Asia
Axle Spec. Number
M = Meritor
F = Front
S = Non-Drive Steer Axle
GAWR Pounds or Tonnes
Ref: Target Market
Beam, King Pin, Bushing Variation
1 = Forged I-Beam, Straight King Pins —
Easy Steer™ Bushings
2 = Forged I-Beam, Tapered King Pins —
Needle Bearings
3 = Forged I-Beam, Alloy Material, India
4 = Forged I-Beam, Straight King Pins —
Bronze Bushings
Brake Type
B = Reaction Beam
Disc Brake
C = Air Disc Brake
D = Wedge Brake (Dual
Air Chambers)
E = Wedge Brake (Dual
Hydraulic Cylinders)
F = Wedge Brake (Single
Hydraulic Cylinder)
G = DuraPark® Hydraulic
Drum
H = Quadraulic Disc
K = DiscPlus™ Air Disc
Q PlusTM Cam Brake
None
“P” Series Cam Brake
“Q” Series Cam Brake
Cast PlusTM Brake
Wedge Brake (Single
Air Chamber)
T = “T” Series Cam Brake
W = “W” Series Cam
Brake
Z = Non-Meritor Brake
L
N
P
Q
R
S
=
=
=
=
=
=
6
1003426d
Figure 6.5
Inspection
Wear and Damage
Parts
Inspect parts of the axle for wear and damage. Look for bent or
cracked parts. Replace all worn or damaged parts.
Fasteners
Pivot Points
1.
Verify that all the fasteners are tightened to the specified
torque.
Verify that the pivot points are not loose. Verify that the pivot
points are lubricated.
2.
Use a torque wrench to check the torque. As soon as the
fastener starts to move, record the torque. Correct if
necessary.
3.
Replace any worn or damaged fasteners.
Operation
Verify that all the parts move smoothly through the complete
turning radius.
Meritor Maintenance Manual 1 (Revised 08-06)
67
mm1.fm.book Page 68 Thursday, August 24, 2006 12:29 PM
6 Front Non-Drive Steer Axles
Tire Wear
Figure 6.7
Inspect the tires for wear patterns that indicate suspension damage
or misalignment. Correct if necessary.
Steering Arm Bolts
Check the torque on all bolt-on steering arm bolts every
200,000 miles (320 000 km).
Draw Key Nuts
Tighten the draw key nuts to 30-45 lb-ft (41-61 N폷m) at the
following intervals. Figure 6.6. @
1000321c
Figure 6.7
앫 After the first 6,000 miles (10 000 km) of new vehicle operation
앫 Every 36,000 miles (58 000 km) of operation
Figure 6.8
Figure 6.6
DRAW KEY NUT
30-45 LB-FT (41-61 N•m)
PRY BAR
1000322d
Figure 6.8
1000004b
5.
Set the dial indicator on ZERO.
6.
Use the pry bar to push the knuckle UPWARD. Record the
reading on the dial indicator.
Figure 6.6
Steering Knuckle Vertical End Play
Axles with Conventional Wheel Ends
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving.
2.
Use a jack to raise the vehicle until the front wheels are off the
ground. Support the front axle with safety stands.
3.
Install a dial indicator with the base on the I-beam and the tip
on the top knuckle cap. Figure 6.7.
4.
Place a pry bar between the boss for the tie rod arm and the
I-beam. Push the knuckle to the BOTTOM of vertical travel.
Figure 6.8.
앫 If the reading is ZERO: Remove the knuckle. Remove the
shims from the shim pack. Refer to Maintenance Manual 2,
Front Non-Drive Steer Axles, for more information.
앫 If the reading is more than the correct end play
specifications shown in the table below: Remove the
knuckle. Add shims to the shim pack. Refer to Maintenance
Manual 2, Front Non-Drive Steer Axles, for more
information.
Table AP: End Play Specifications
68
Meritor Maintenance Manual 1 (Revised 08-06)
New or Rebuilt
0.001-0.010-inch
(0.025-0.254 mm)
In-Service Axles
0.001-0.030-inch
(0.025-0.762 mm)
mm1.fm.book Page 69 Thursday, August 24, 2006 12:29 PM
6 Front Non-Drive Steer Axles
Axles with Unitized Wheel Ends
Driver-Side Knuckle
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Set the parking brake.
A.
To check the driver-side knuckle, turn the wheels
STRAIGHT ahead.
2.
Use a jack to raise the vehicle until the front wheels are off the
ground. Support the front axle with safety stands.
B.
Install a dial indicator with the base onto the steering arm.
3.
Install a dial indicator for each side of the axle beam.
NOTE: The wood block should have a hole that allows clearance for
the lower king pin grease fitting.
Curbside Knuckle
C.
Place a jack and a wood block under the lower king pin
cap area.
D.
Place the dial indicator tip onto the exposed king pin top.
Set the dial indicator to ZERO.
E.
Move the jack up. Measure and record the dial indicator
reading. Lower the jack.
A.
Turn the wheels STRAIGHT ahead. Install the dial base
onto the axle beam.
B.
Place the dial indicator tip onto the upper king pin cap.
C.
Place a jack and a wood block, with a hole that allows
clearance for the lower king pin grease fitting, under the
lower king pin cap area. Figure 6.9.
D.
Set the dial indicator to ZERO.
Alternate Method to Measure End Play
E.
Raise the jack until you start to lift the axle beam off the
safety stands. Measure and record the dial indicator
reading.
A.
As an alternative method to measure end play, turn the
wheels to the RIGHT for a curbside knuckle or LEFT for a
driver-side knuckle measurement.
F.
Lower the jack.
B.
Place a pry bar between the tie rod arm and the axle
beam. Figure 6.10.
C.
Set the dial indicator to ZERO.
D.
Lift the knuckle UPWARD using a pry bar. Record the
reading on the dial indicator.
6
Figure 6.9
CURBSIDE
4.
Compare the reading you obtained with the end play
specifications below.
앫 If the reading is ZERO: Remove the knuckle. Remove
shims from the shim pack. Refer to Maintenance Manual 2,
Front Non-Drive Steer Axles, for more information.
WOOD
BLOCK
Figure 6.9
1000005c
앫 If the reading is more than the correct end play
specifications: Remove the knuckle. Add shims to the
shim pack. Refer to Maintenance Manual 2, Front
Non-Drive Steer Axles, for more information.
Table AQ: End Play Specifications
New or Rebuilt
0.001-0.010-inch
(0.025-0.254 mm)
In-Service Axles
0.001-0.030-inch
(0.025-0.762 mm)
Meritor Maintenance Manual 1 (Revised 08-06)
69
mm1.fm.book Page 70 Thursday, August 24, 2006 12:29 PM
6 Front Non-Drive Steer Axles
Figure 6.10
Figure 6.11
KING PIN
TOP
CONVENTIONAL WHEEL END — DRIVER SIDE
1000323d
TIE ROD
ARM
Figure 6.11
1000006c
Figure 6.10
Figure 6.12
Upper and Lower King Pin Bushings
Wheel-to-Hub Mounting
To help determine the cause of movement and looseness, first
check the wheel-to-hub mounting.
1.
Verify that the wheel is mounted correctly and all wheel-end
fasteners and hardware are secure.
2.
Apply the service brake to lock the hub and spindle assembly
together.
앫 If movement is detected: The king pin or king pin
bushings are most likely worn.
앫 If applying the service brake eliminates the movement:
Proceed to Detailed Inspection to determine the unitized
wheel-end hub end play.
Axles with Conventional and Unitized Wheel Ends
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Set the parking brake.
2.
Use a jack to raise the vehicle until the front wheels are off the
ground. Support the front axle with safety stands.
3.
Check the upper king pin bushing for wear. Install a dial
indicator with the base on the I-beam and the tip against the
side of the top of the knuckle. Figure 6.11 and Figure 6.12.
70
Meritor Maintenance Manual 1 (Revised 08-06)
UNITIZED WHEEL END — DRIVER SIDE
1000007e
Figure 6.12
4.
Set the dial indicator to ZERO.
5.
Move the top of the tire side-to-side TOWARD and AWAY from
the vehicle.
앫 If the indicator moves a total of 0.010-inch (0.254 mm):
The upper bushing is worn or damaged. Replace both
bushings in the knuckle. Refer to Maintenance Manual 2,
Front Non-Drive Steer Axles, for more information.
Figure 6.11 and Figure 6.12.
mm1.fm.book Page 71 Thursday, August 24, 2006 12:29 PM
6 Front Non-Drive Steer Axles
6.
Check the lower king pin bushing. Install a dial indicator so that
the base is on the I-beam and that the tip is against the side of
the bottom of the knuckle. Figure 6.13 and Figure 6.14.
Figure 6.13
Wheel-to-Hub Mounting
To help determine the cause of movement and looseness, first
check the wheel-to-hub mounting.
1.
Verify that the wheel is mounted correctly and all wheel-end
fasteners and hardware are tightened to the correct
specification.
2.
Apply the service brake to lock the hub and spindle assembly
together.
앫 If you detect movement or looseness: The king pin or
king pin bushings are most likely worn.
CONVENTIONAL WHEEL END — FRONT VIEW CURBSIDE
앫 If applying the service brake eliminates the movement:
Proceed to the detailed inspection procedure in this section
to determine the unitized wheel-end hub end play.
1000324d
Figure 6.13
Figure 6.14
Basic Inspection
6
After the initial 200,000-mile (321 800 km) detailed inspection,
perform a basic inspection at each scheduled preventive
maintenance interval, not to exceed 50,000-mile (80 467 km)
intervals.
If the Vehicle is Equipped with ABS on the Steer Axle
UNITIZED WHEEL END — FRONT VIEW CURBSIDE
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving.
2.
Raise the vehicle so that the front wheels are off the ground.
Support the vehicle with safety stands. Do not use a jack to
support the vehicle.
3.
Visually inspect the unitized wheel end as you rotate the tire
and unitized wheel-end assembly. Verify that it rotates
smoothly and without noise. While rotating the wheel, grasp
the brake chamber to feel for unitized wheel-end hub vibration.
1000008e
Figure 6.14
7.
Set the dial indicator to ZERO.
8.
Move the bottom of the tire side-to-side TOWARD and AWAY
from the vehicle.
앫 If the dial indicator moves a total of 0.010-inch
(0.254 mm): The lower bushing is worn or damaged.
Replace both bushings in the knuckle. Refer to
Maintenance Manual 2, Front Non-Drive Steer Axles,
for more information. Figure 6.13 and Figure 6.14.
Unitized Wheel End
The unitized wheel end is sealed and greased for life and does not
require lubrication. If you disassemble, or attempt to repair or
lubricate a unitized wheel-end assembly, you will void Meritor’s
warranty. The basic and detailed inspection procedures provided
in this manual do not instruct you to disassemble the unitized
wheel end.
앫 If the tire and unitized wheel-end assembly does not
rotate smoothly, or you hear noise or feel wheel-end
hub vibration during rotation: Perform a detailed
inspection. Refer to the detailed inspection procedure in
this section.
앫 If the wheel end rotates smoothly: Proceed to Step 4.
Meritor Maintenance Manual 1 (Revised 08-06)
71
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6 Front Non-Drive Steer Axles
4.
Grasp the tire and wheel-end assembly at the 9 and 3 o’clock
positions. Check for vertical and horizontal movement. With
your hands, apply approximately 50 lb (23 kg) of force to the
assembly. You should not feel or see any looseness or
movement.
앫 If you feel or see any movement or looseness in the
tire and wheel-end assembly: Perform a detailed
inspection to determine the cause of the movement, such
as worn king pin bushings or pins; wheel-to-hub-mounting
end play; unitized wheel-end hub end play; or a
combination of them all. To determine unitized wheel-end
hub end play, refer to the detailed inspection procedure in
this section.
If other front axle components, such as king pin bushings,
require inspection or service, refer to the appropriate
procedures in this manual.
4.
Verify that the unitized wheel end rotates smoothly and without
noise. While rotating the wheel, grasp the brake chamber to
feel for unitized wheel-end hub vibration.
앫 If the tire and unitized wheel-end assembly does not
rotate smoothly, or you hear noise or feel wheel-end
hub vibration during rotation: Replace the unitized
wheel-end hub.
앫 If the wheel end rotates smoothly: Proceed to Step 5.
5.
Remove the wheel and drum. Attach the magnetic base of a
dial indicator onto the end of the spindle. Figure 6.16. Touch
the indicator stem perpendicular against the unitized wheel
end’s mounting face.
Figure 6.16
Detailed Inspection
Perform detailed inspections after the initial 200,000 miles
(321 800 km) of operation and after every additional 200,000 miles
(321 800 km) of operation thereafter.
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving.
2.
Remove the hubcap. The outboard and inboard seals may
purge small amounts of grease that are visible during
inspection. Figure 6.15. This is a normal occurrence.
DIAL
INDICATOR
4000308a
Figure 6.16
6.
Set the dial indicator to ZERO. Do not rotate the wheel end.
Place your hands at the 9 and 3 o’clock positions.
7.
Push the unitized wheel end straight IN. Note the reading. Pull
the unitized wheel end straight OUT. Note the reading.
Figure 6.15
GREASE
앫 If the total movement of the dial indicator is less than
0.003-inch (0.08 mm): Inspection is complete. Return the
vehicle to service.
4000299b
Figure 6.15
3.
72
Raise the vehicle so that the front wheels are off the ground.
Support the vehicle with safety stands. Do not use a jack to
support the vehicle.
Meritor Maintenance Manual 1 (Revised 08-06)
앫 If the total movement of the dial indicator is 0.003-inch
(0.08 mm) or greater: Remove the outer bearing nut and
tabbed washer. Tighten the inner wheel bearing nut to
500-700 lb-ft (679-949 N폷m) while rotating the unitized
wheel end a minimum of five rotations. @
mm1.fm.book Page 73 Thursday, August 24, 2006 12:29 PM
6 Front Non-Drive Steer Axles
NOTE: The inner wheel bearing nut and the outer wheel bearing nut
are identical, but the torque values are different.
8.
Install the tabbed washer and outer wheel bearing nut onto the
spindle. Tighten the outer wheel bearing nut to 200-300 lb-ft
(271-476 N폷m). @
9.
Reattach the dial indicator. Set the dial indicator to ZERO.
Do not rotate the wheel end. Place your hands at the 9 and
3 o’clock positions.
Figure 6.17
BALL/STUD
BALL/STUD
NATURAL
PIVOT
WEAR
NATURAL
BEARING
WEAR
10. Push the unitized wheel end straight IN. Note the reading. Pull
the unitized wheel end straight OUT. Note the reading.
앫 If the total movement of the dial indicator is greater
than 0.003-inch (0.08 mm), but less than 0.006-inch
(0.15 mm): Record the measurement in a maintenance
log, and perform a basic inspection at the next
regularly-scheduled maintenance interval, or not to exceed
50,000 miles (80 467 km), whichever comes first.
After you’ve taken the measurement, bend the parts of the
tabbed washer that protrude over the flats of the outer
wheel bearing nut and the inner wheel bearing nut. Bend
the washer a minimum of one flat edge to each nut.
Inspection is complete. Return the vehicle to service.
BALL/STUD
SOLID STEEL
BEARING SURFACE
1003401f
6
Figure 6.17
1.
Park the vehicle on a level surface with the wheels STRAIGHT.
Block the wheels to prevent the vehicle from moving. Set the
parking brake. Figure 6.18.
Figure 6.18
앫 If the total movement of the dial indicator is 0.006-inch
(0.15 mm) or greater: Replace the unitized wheel-end
hub.
Tie Rod and Cross Tube Assembly
NOTE: Do not grease the tie rod assembly before you perform the
inspection.
You may not be able to detect loose or worn tie rod ends during
operation. Under normal operating conditions, wear occurs over
time. The preload bearings inside each tie rod end provide less
resistance, which can affect steering control, front tire wear, and
other axle components.
Regularly-scheduled inspection and maintenance helps to minimize
the effects of tie rod end wear on the vehicle. Refer to Table AR and
Table AS in this section for inspection intervals. Figure 6.17.
TIE
TIE
ROD
ROD
END
ARM
CROSS
TUBE
1000325b
Figure 6.18
2.
Raise the vehicle so that the front wheels are off the ground.
Support the vehicle with safety stands. Do not use a jack to
support the vehicle.
3.
With the engine off, turn the wheels from full left to full right.
Return to the straight-ahead position. This step will require
more force for vehicles with the power steering off.
Meritor Maintenance Manual 1 (Revised 08-06)
73
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6 Front Non-Drive Steer Axles
4.
Check the tie rod boot for cracks, tears or other damage. Also
check the boot seals for damage. Replace the entire tie rod end
if the boot is damaged or missing. Figure 6.19.
6.
Check that the tie rod end is threaded correctly into the cross
tube and installed deeper than the end of the cross tube slot.
The tie rod end must be visible the entire length of the cross
tube slot. Figure 6.21.
Figure 6.19
Cracked or torn boot
requires entire
tie rod end replacement.
Figure 6.21
Tie rod end installed
deeper than the end of
the cross tube slot.
4000283b
Figure 6.19
TIE ROD
CROSS
TUBE SLOT
END
WARNING
Verify that a cotter pin is installed through the tie rod end,
and the tie rod end nut is tightened to the correct torque
specification. Replace a missing cotter pin and tighten a loose
tie rod end nut. A missing cotter pin or loose tie rod end nut
can cause loss of steering control. Serious personal injury and
damage to components can result.
5.
Tie rod threads
must be visible
the entire length
of the cross tube slot.
4000285a
Figure 6.21
7.
Check that the grease fittings are installed. Replace a damaged
grease fitting.
앫 If the tie rod ends are non-greaseable: Do not install a
grease fitting. Figure 6.22.
Check that the tie rod nut is installed and secured with a
cotter pin.
Figure 6.22
앫 If the cotter pin is missing: Tighten the tie rod end nut to
the correct specification. Install a new cotter pin. Always
tighten the tie rod nut to the specified torque when setting
the cotter pin. Do not back-off the nut to insert the cotter
pin. Figure 6.20.
ALTERNATE
GREASE
FITTING
LOCATIONS
Figure 6.20
Missing cotter pin
indicates unsafe
condition and requires
immediate replacement.
4000289a
Figure 6.22
8.
STEERING
KNUCKLE
Figure 6.20
74
Meritor Maintenance Manual 1 (Revised 08-06)
4000284a
By hand or using a pipe wrench with jaw protectors to avoid
gouging the cross tube, rotate the cross tube toward the front
of the vehicle and then toward the rear. After rotating, center
the cross tube between the stop positions.
앫 If the cross tube will not rotate in either direction:
Replace both tie rod ends.
mm1.fm.book Page 75 Thursday, August 24, 2006 12:29 PM
6 Front Non-Drive Steer Axles
9.
Position yourself directly below the ball stud socket. Using both
hands, grasp the assembly end as close to the socket as
possible, no more than 6-inches (152.4 mm) from the end.
Figure 6.24
CROSS
TUBE
CLAMP
CAUTION
Only use your hands to check for movement or looseness of
the tie rod assembly. Do not use a crow bar, pickle fork or
two-by-four. Do not apply pressure or force to the tie rod
assembly ends or joints. Do not rock the tires with the vehicle
on the ground or with the wheels raised. Damage to
components can result.
CRACK
DAMAGE
4000288a
Figure 6.24
10. Apply hand pressure of approximately 100 lbs (45.4 kg) in a
vertical PUSH and PULL motion several times. Check for any
movement or looseness at both tie rod ends. Figure 6.23.
앫 If there is any movement in the tie rod assembly:
Replace both tie rod ends.
Figure 6.23
Department of Transportation Roadside Tie
Rod Assembly Replacement Criteria
When the roadside check indicates tie rod movement of 0.125-inch
(3 mm) or more, immediately remove the vehicle from service to
replace the tie rod. Figure 6.23.
앫 If the roadside check is less than 0.125-inch (3 mm) tie rod
end movement: The vehicle does not need to be immediately
removed from a service run. Schedule a major out-of-service
inspection and maintenance as soon as possible.
Push.
Lubrication
Check movement
by hand.
Tie Rod End
Pull.
4000287a
WARNING
Figure 6.23
CAUTION
Replace bent or damaged cross tubes with original equipment
parts of the same length, diameter and threads. Do not
attempt to straighten a bent cross tube. Damage to
components can result.
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
This procedure refers to all tie rod ends on Meritor non-drive
steer axles.
11. Inspect the cross tube and clamps for damage. Figure 6.24.
앫 If the cross tube is bent or cracked: Replace it. Use
original equipment parts of the same length, diameter and
threads.
앫 If the clamps are damaged: Replace them.
1.
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Set the parking brake.
2.
Turn the vehicle wheels to the STRAIGHT position.
Figure 6.25.
앫 If either clamp has become welded to the cross tube:
Replace the entire cross tube assembly. Use original
equipment parts of the same length, diameter and threads.
Meritor Maintenance Manual 1 (Revised 08-06)
75
6
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6 Front Non-Drive Steer Axles
5.
Figure 6.25
Apply grease into the grease fitting. Discolored old grease
should come out of the purge holes near the boot crimp or
bellows area, typically three or more places. Figure 6.28.
Figure 6.28
SLIDING SEAL TIE
ROD ENDS
Point wheels straight ahead.
TRW — LUBE PURGES
EVENLY FROM BASE OF BOOT
1003405a
Figure 6.25
3.
NON-REMOVABLE AND ALL-WEATHER
BOOT SEAL TIE ROD ENDS
Wipe the grease fitting, seal and boot clean with shop towels.
Figure 6.26.
O & S — LUBE
PURGES FROM THREE
HOLES TOP OF BOOT
Figure 6.26
Always clean off grease
fittings prior to applying lube.
TRW — LUBE
PURGES FROM
BOOT BASE IN EVEN,
SMALL STREAMS
GREASE
FITTING
ALTERNATE
LOCATION
1003422b
URRESKO — LUBE PURGES
FROM TOP OF BOOT
Figure 6.26
4.
Attach either a hand or air pressure grease gun to the grease
fitting. Figure 6.27. If using air pressure, do not exceed 150 psi
(1035 kPa).
O & S — LUBE
PURGES FROM THREE
HOLES TOP OF BOOT
Figure 6.27
O & S — NON-GREASEABLE
1003424c
Figure 6.28
Apply grease into all grease fittings where required.
1003423b
Figure 6.27
76
Meritor Maintenance Manual 1 (Revised 08-06)
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6 Front Non-Drive Steer Axles
6.
7.
If the tie rod end is designed for lube service and it does not
accept grease, perform the following procedure.
Axles with Unitized Wheel Ends
1.
Park the vehicle on a level surface. Block the wheels to keep
the vehicle from moving. Set the parking brake.
Inspect the threaded grease fitting hole in the tie rod end
and remove any obstructions.
2.
Verify that the tires touch the ground. DO NOT RAISE THE
VEHICLE.
C.
Install a new grease fitting.
3.
Clean off all grease fittings prior to lubrication.
D.
Continue the lubrication procedure.
4.
Lubricate the king pins through the grease fittings on the top
and bottom king pin caps. Figure 6.30.
A.
Remove the grease fitting.
B.
Apply grease until all old grease is purged from the boot.
Figure 6.30
King Pins
GREASE
FITTING
Axles with Conventional Wheel Ends
1.
Park the vehicle on a level surface. Block the wheels to keep
the vehicle from moving. Set the parking brake.
2.
Verify that the tires touch the ground. DO NOT RAISE THE
VEHICLE.
3.
Clean off all grease fittings prior to lubrication.
4.
Lubricate the king pins through the top and the bottom grease
fittings. Figure 6.29.
6
GREASE
FITTING
1000011b
Figure 6.30
5.
Figure 6.29
SIDE
GREASE
FITTING
Lube must
come from here.
TOP
GREASE
FITTING
Force lubricant into the upper and lower king pin grease fitting
caps until new lubricant flows from between the upper axle
beam end and the knuckle, and the lower axle beam end and
the knuckle. Figure 6.30.
Ball Studs on the Steering Arm and the Tie
Rod Arm Ends
Lube must
come from
here.
Axles with Conventional and Unitized Wheel Ends
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Set the parking brake.
2.
Verify that the tires touch the ground. DO NOT RAISE THE
VEHICLE.
3.
Clean off all grease fittings prior to lubrication.
4.
Apply lubricant until new lubricant comes from the boot.
Figure 6.31 and Figure 6.32.
1000327b
Figure 6.29
5.
Apply lubricant until new lubricant comes from between the
upper shim pack and thrust bearing seal.
6.
Apply lubricant into the bottom fitting until new lubricant
purges and fills the thrust bearing.
Meritor Maintenance Manual 1 (Revised 08-06)
77
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6 Front Non-Drive Steer Axles
4.
Figure 6.31
CONVENTIONAL
Force the specified lubricant from the large end of the cones
into the cavities between the rollers and cage. Pack the hub
between the bearing cups with lubricant to the level of the
smallest diameter of the cups. Figure 6.33.
Figure 6.33
LUBE
Lube must
come from here.
GREASE
FITTING
1000329a
Figure 6.31
1000330b
Figure 6.32
Figure 6.33
UNITIZED
Lube must come
from here.
GREASE
FITTING
1000012b
Figure 6.32
Grease-Lubricated Wheel Bearings
Axles with Conventional Wheel Ends
NOTE: This procedure applies to hubs with grease-lubricated wheel
bearings.
1.
Park the vehicle on a level surface. Block the wheels to keep
the vehicle from moving. Set the parking brake.
2.
Remove the tire and wheel assembly. Remove and
disassemble the hub. Refer to Wheel Ends in Maintenance
Manual 2, Front Non-Drive Steer Axles. To obtain this
publication, refer to the Service Notes page on the front inside
cover of this manual.
3.
Remove the old lubricant from all parts. Discard the seals.
Inspect the wheel bearings for wear or damage. Replace worn
or damaged bearings. Refer to Maintenance Manual 2, Front
Non-Drive Steer Axles. To obtain this publication, refer to the
Service Notes page on the front inside cover of this manual.
5.
Install the inner and outer bearing cones into the cups in the
hubs. The bearing cups must be pressed tight against the
shoulder in the hubs.
6.
Install new wheel seals into the hubs.
7.
Install the hub and the wheel and tire assembly. Install the
outer wheel bearing cone into the hub. Install the adjusting nut.
8.
Adjust the wheel bearings.
Oil-Lubricated Wheel Bearings
Axles with Conventional Wheel Ends
NOTE: This procedure applies to hubs with oil-lubricated wheel
bearings.
1.
Check the level on the cap. If the oil level is not at the specified
level on the cap, remove the fill plug.
2.
Add the specified oil until the oil is at the specified level.
Figure 6.34.
Figure 6.34
78
Meritor Maintenance Manual 1 (Revised 08-06)
OIL
LEVEL
Figure 6.34
1000331c
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6 Front Non-Drive Steer Axles
Check and Adjust
Tighten Draw Key Nuts
Steering Arm Bolts
Axles with Conventional and Unitized Wheel Ends
WARNING
Take care when you use Loctite® adhesive to avoid serious
personal injury. Read the manufacturer’s instructions before
using this product. Follow the instructions carefully to prevent
irritation to the eyes and skin. If Loctite® adhesive material
gets into your eyes, follow the manufacturer’s emergency
procedures. Have your eyes checked by a physician as soon
as possible.
1.
Check the steering arm bolts for minimum torque. Refer to the
table below.
NOTE: This procedure applies to all except 901, 903 and
970 Series axles. These axles do not use a draw key. Refer to the
identification tag on the front of the axle beam.
Tighten the nuts on the side of the knuckle that hold the draw keys
to 30-45 lb-ft (41-61 N폷m) at the following times. Figure 6.35 and
Figure 6.36. @
앫 After the first 6,000 miles (10 000 km) of new vehicle operation
앫 Every 36,000 miles (58 000 km) of operation
Figure 6.35
Axle
Torque lb-ft (N폷m)
MFS-6
215-265 (290-360)
MFS-7 or MFS-8
360-470 (490-638)
All other axles
300-450 (406-610)
6
CONVENTIONAL
Tighten draw key
nut to 30-45 lb-ft
(41-61 N•m).
앫 If steering arm bolt torque has fallen below minimum
torque:
A.
B.
2.
3.
Remove the bolts. Clean all the threads. Install new
Loctite® 680 adhesive, Meritor part number
2297-K-5523.
Tighten the bolts to specification. Refer to the table
above.
1000332b
Figure 6.35
Figure 6.36
UNITIZED
Check the steering arm bolt torque every 200,000 miles
(320 000 km) or 24 months.
DRAW KEY NUT
30-45 LB-FT
(41-61 N•m)
Refer to Maintenance Manual 2, Front Non-Drive Steer Axles,
for Dri-Loc® fastener installation procedures. To obtain this
publication, refer to the Service Notes page on the front inside
cover of this manual.
1000013c
Figure 6.36
Meritor Maintenance Manual 1 (Revised 08-06)
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6 Front Non-Drive Steer Axles
Lubrication Intervals and Specifications
Refer to the tables in this section for lubrication, inspection and maintenance schedules based on vehicle usage.
Table AR: Vocational Groups
Group Number
Typical Vocations
Vehicle Build
Typical Operation Conditions
1
On-highway or turnpike,
linehaul only
After July 1, 1996
High mileage operation, more than
50,000 miles/year (80 500 km/year)
2
3
Before July 1, 1996,
use category 3
Fire and rescue, city delivery,
inner city coach, heavy haul,
school bus, motor home, transit
coach
After July 1, 1996
Logging, oil field, construction,
heavy haul, yard tractor (highway
licensed), residential refuse
ALL
Before July 1, 1996,
use category 3
95% on-highway/turnpike surface
Lower mileage operation, less than
50,000 miles/year (80 500 km/year)
Low mileage operation, less than
25,000 miles/year (40 250 km/year)
Heavy-duty service with substantial off-road
operation
4
Mining, yard tractor
(non-highway licensed), and land
fill refuse
Heavy-duty service
5
Mining, logging and construction
Severe duty 80-100% off highway
80
Meritor Maintenance Manual 1 (Revised 08-06)
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6 Front Non-Drive Steer Axles
Table AS: Lubrication, Inspection and Maintenance Schedule
Service Intervals
5,000
miles
(8050
km)/100
hours
First
6,000
miles
(10 000
km) of
operation
48
Component
hours
Tie Rod Ends
Group 1
Vocations
Group 2
Vocations
Group 3
Vocations
Group 4
I,L*
Vocations
Group 5
I,L*
Vocations
Inspect the Tie Rod Assembly for Movement
Group 1
Vocations
Group 2
Vocations
Group 3
Vocations
Group 4
I
Vocations
Group 5
I
Vocations
Tie Rod End Shop Inspection
Ball Studs on
Steering
Arms
Easy Steer
Plus Axle Ball
Studs
Sealed Axle
Ball Studs
King Pins and
Bushings
Steering
Arms Bolts
Thrust
Bearings
10,000
miles
(16 100
km)
20,000
miles
(32 200
km)
I
36,000
miles
(58 000
km)
40,000
miles
(64 000
km)
50,000
miles
(80 500
km)
100,000
miles
(160 000
km)
I
L*
200,000
miles
320 000
km
L*
I,L*
6
I
I
I
L*
I
I
L*
I
L*
Meritor Maintenance Manual 1 (Revised 08-06)
81
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6 Front Non-Drive Steer Axles
Table AS: Lubrication, Inspection and Maintenance Schedule
Service Intervals
First
5,000
6,000
miles
miles
(8050
(10 000
48
km)/100 km) of
Component
hours hours
operation
Steering Knuckle Vertical End Play Inspection
Group 1
Vocations
Group 2
Vocations
Group 3
Vocations
Group 4
I
Vocations
Group 5
I
Vocations
Upper and Lower King Pin Bushings for Wear
Group 1
Vocations
Group 2
Vocations
Group 3
Vocations
Group 4
I
Vocations
Group 5
I
Vocations
Draw Key
T
Nuts
Sealed Hub
Unit
Inspection
10,000
miles
(16 100
km)
20,000
miles
(32 200
km)
36,000
miles
(58 000
km)
40,000
miles
(64 000
km)
50,000
miles
(80 500
km)
100,000
miles
(160 000
km)
200,000
miles
320 000
km
I
I
I
I
I
I
T
I
I = Inspect
L = Lubricate
T = Tighten to specified torque
* If power washers are used during vehicle cleaning operations, lubrication intervals need to be adjusted. Frequent power-washed vehicles will require more
frequent lubrication.
82
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6 Front Non-Drive Steer Axles
Lubricant
Table AT: Front Non-Drive Axle Greasing Specifications
Grease*
Meritor Specification
NLGI Grade
Grease Classification
Outside Temperature
Multi-Purpose Grease*
O-617-A
1
6% Lithium 12-Hydroxyl
Stearate
O-617-B
2
8% Lithium 12-Hydroxyl
Stearate
Refer to the grease
manufacturer’s
specifications for the
temperature service
limits.
* Meritor recognizes that industry trends are moving toward increased selection and usage of synthetic grease in vehicle maintenance. However, some seals
are known to expand when in contact with synthetic grease. Consult your local Meritor representative for synthetic grease application references BEFORE
using any synthetic grease when performing axle service and maintenance.
Troubleshooting
6
Table AU: Front Non-Drive Steer Axle Diagnostic Table
Condition
Cause
Correction
Tires wear out quickly or
have uneven tire tread
wear.
Tires have incorrect air pressure
Place the specified air pressure in the tires.
Tires out-of-balance
Balance or replace the tires.
Incorrect tandem axle alignment
Align the tandem axles.
Incorrect toe-in setting
Adjust the toe-in specified setting.
Incorrect steering arm geometry
Service the steering system as necessary.
Excessive wheel-end play exists
Readjust the wheel bearings.
Power steering system pressure low
Repair the power steering system.
Steering gear linkage not assembled correctly
Assemble the steering gear correctly.
Steering linkage needs lubrication
Lubricate the steering linkage.
King pins binding
Replace the king pins.
Incorrect steering arm geometry
Service the steering system as necessary.
Caster out-of-adjustment
Adjust the caster as necessary.
Tie rod ends hard to move
Replace the tie rod ends.
Worn thrust bearing
Replace the thrust bearing.
Tie rod ends require lubrication
Lubricate the cross tube ends. Verify that the lubrication
schedule is followed.
Severe operating conditions
Increase the frequency of inspection and lubrication
intervals.
Damaged boot on tie rod end
Replace the boot.
Vehicle is hard to steer.
Tie rod ends are worn and
require replacement.
Meritor Maintenance Manual 1 (Revised 08-06)
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6 Front Non-Drive Steer Axles
Table AU: Front Non-Drive Steer Axle Diagnostic Table
Condition
Cause
Correction
Bent or broken cross tube,
tie rod end ball stud,
steering arm or tie rod end.
Component requires
replacement.
Too much pressure in the power steering
system, pressure exceeds OEM specification
Adjust the power steering system to the specified
pressure.
Power steering system cut-off pressure,
out-of-adjustment
Adjust the power steering system to the specified
pressure.
Vehicle operated under severe conditions
Verify that the vehicle is operated correctly.
Add-on type of power steering system not
installed correctly
Correctly install the add-on power steering system.
Steering gear overtravel poppets incorrectly
set or malfunctioning
Check for correct operation or adjust the overtravel of the
poppets to the manufacturer’s specifications.
Axle stops incorrectly set
Set the axle stops to the manufacturer’s specification.
Drag link fasteners tightened higher than
vehicle manufacturer’s specifications
Tighten the drag link fasteners to the vehicle
manufacturer’s specified torque.
Lack of lubrication or incorrect lubricant
Lubricate the linkage with the specified lubricant.
Power steering stops out-of-adjustment
Adjust the stops to the specified dimension.
Worn or missing seals and gaskets
Replace the seals and gaskets.
Incorrect lubricant
Lubricate the axle with the specified lubricant.
Axle not lubricated at scheduled frequency
Lubricate the axle at the scheduled intervals.
Incorrect lubrication procedures
Use the correct lubrication procedures.
Lubrication schedule does not match
operating conditions
Change the lubrication schedule to match the operating
conditions.
Caster out-of-adjustment
Adjust the caster.
Wheels or tires out-of-balance
Balance or replace the wheels or tires.
Worn shock absorbers
Replace the shock absorbers.
Worn or broken steering
ball stud
Worn king pins and king
pin bushings
Vibration or shimmy of
front axle during operation
84
Meritor Maintenance Manual 1 (Revised 08-06)
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7 Brakes
Hazard Alert Messages
7 Brakes
Figure 7.1
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
ASBESTOS AND NON-ASBESTOS
FIBERS WARNING
Some brake linings contain asbestos fibers, a cancer and lung
disease hazard. Some brake linings contain non-asbestos
fibers, whose long-term effects to health are unknown. You
must use caution when you handle both asbestos and
non-asbestos materials.
4000317n
Q Plus™
Figure 7.1
Figure 7.2
Cam Brakes
Technical Publications
7
How to Obtain Additional Maintenance and Service
Information
Refer to the publications in Table AV. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
4000319n
Cast Plus™
Figure 7.2
Table AV: Publications
Model
Manual
Cam Brakes and Automatic
Slack Adjusters
Maintenance Manual 4
Q Plus™ LX500 and MX500
Cam Brakes
Maintenance Manual
MM-96173
Cam Brakes
Failure Analysis Manual
TP-0445
Figure 7.3
Description
4000321n
Q Plus™ and Cast Plus™; and Q, P and T Series
Meritor cam brakes are air-actuated, cam-operated, two-shoe
brakes with each shoe mounted on a separate anchor pin. The
brakes are available with automatic slack adjusters and can be
assembled with air chambers. Figure 7.1, Figure 7.2, Figure 7.3
and Figure 7.4.
P Series
Figure 7.3
Meritor Maintenance Manual 1 (Revised 08-06)
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7 Brakes
Identification
Figure 7.4
Cam brakes are identified as follows.
앫 A model number tag for the brake assembly is located on the
camshaft tube.
앫 An example of a part number format for a 16.5 Q Plus™ brake
is QP1 1657 1234.
4000322n
T Series
In addition to the model number tag on the cam tube, a brake shoe
label is attached to the brake shoe web. This label provides
information on brake type, lining material and service parts
replacement number. Figure 7.5.
Figure 7.4
Figure 7.5
Q Plus™ LX Cam Brake Package with the Extended
Lube Feature
MERITOR SERVICE
PARTS, SHOE AND
LINING ASSEMBLY,
PART NUMBER
This package is available for on-highway linehaul, city delivery and
school bus applications, and includes the following features.
앫 For linehaul applications, camshafts and automatic slack
adjusters do not require lubrication for three years or
500,000 miles (800 000 km), whichever comes first.
앫 For city delivery and school bus applications, camshafts and
automatic slack adjusters do not require lubrication for one year
or unlimited miles, whichever comes first.
MERITOR LINING
MATERIAL
DESIGNATION
BRAKES
LINING:
REPLACE WITH:
MA212
S MA 212 4707 QP
The Meritor brake warranty does not cover the cost of any
repairs to a covered product that might result from the use
of non-genuine Meritor parts. See Pub. SP9260.
앫 Meritor factory-installed automatic slack adjusters
Q Plus™ MX Cam Brake Extended Maintenance
Package Option
This package is available for on-highway linehaul applications only
and includes the following features.
앫 Proprietary friction material on five-inch wide shoes for front
axles, and eight-inch wide shoes for rear axles for more
wearable volume do not require reline for three years or
500,000 miles (800 000 km), whichever comes first.
앫 Camshafts and automatic slack adjusters do not require
lubrication for three years or 500,000 miles (800 000 km),
whichever comes first.
앫 Meritor factory-installed automatic slack adjusters
86
Meritor Maintenance Manual 1 (Revised 08-06)
Shoe
FMSI
S MA 212 4707 QP
Meritor Brand
Designation
(MA = Meritor
R = Rockwell)
Brake Type
Designation
Friction Mix
4002887a
Figure 7.5
mm1.fm.book Page 87 Thursday, August 24, 2006 12:29 PM
7 Brakes
The brake shoe lining also contains identification. Figure 7.6. The
information that exists on the edge code of the lining is listed in the
following order.
Figure 7.6
EXAMPLE: MERITOR MA212 FF
4707 ANC 6133 D-159 53076
앫 Meritor stamped logo
앫 Lining mix designation
앫 Friction code
앫 Friction Material Standards Institute (FMSI) number, four to
eight spaces
4002661b
앫 Block type
Figure 7.6
앫 Meritor part number, last four digits
앫 Word drawing engineering change letter
앫 Julian date, four or five characters
Model Nomenclature
Refer to Figure 7.7 for an explanation of brake model numbers.
Figure 7.7
7
Q Plus™ Cam Brakes
Model Numbers and Designations
Letters other than these
are for older Q design
(not Q Plus™)
P = Plus
L = LX500
V = MX500
Q = Quick Change
S = Stamped Spider
K = Integral Knuckle
C = Cast Plus™
Brake Size
1540 = 15" x 4"
1550 = 15" x 5"
1560 = 15" x 6"
1570 = 15" x 7"
1586 = 15" x 8.6"
1655 = 16-1/2" x 5"
1656 = 16-1/2" x 6"
1657 = 16-1/2" x 7"
1658 = 16-1/2" x 8"
16586 = 16-1/2" x 8.6"
XXXX 1657 1234
Specification Number
1 = With Manual Slack (Export Only)
2 = With Automatic Slack
3 = With Manual Slack and Air Chamber
4 = With Automatic Slack and Air Chamber
5 = Less Slack but with Air Chamber Supplied
6 = Less Slack and Less Air Chamber
A through Z
H = Heavy-Duty Features
T = TracLok™ Feature
W = Wear Sensor Installed
Place holder needed for 16508 brakes
NOTE: For other Meritor brake models, please consult
your Meritor sales or service manager.
4002715b
Figure 7.7
Meritor Maintenance Manual 1 (Revised 08-06)
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7 Brakes
Important Information
Meritor automatic slack adjusters (ASAs) should not need to be
manually adjusted in service. ASAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ASA,
brake actuator or other system components.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ASA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
For Meritor brake adjustment, refer to the brake adjustment tables
in this section. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
Cam Brake Inspection Intervals and
Procedures
On-Highway Linehaul Applications
Q Plus™, Cast Plus™ and Q Series Brakes
Every 100,000 miles (160 000 km) or every six months, whichever
comes first.
P Series Brakes
Q Plus™ LX500 and MX500 Cam Brakes
with Automatic Slack Adjusters
The Q Plus™ LX500 and MX500 cam brake packages include
factory-installed Meritor automatic slack adjusters. Q Plus™ LX500
and MX500 cam brakes and slack adjusters do not require
lubrication for an extended period of time. Refer to the table below.
The camshaft hardware, seals, bushings and washers, do not
require replacement for the same time period.
However, you must continue to observe all other brake preventive
maintenance schedules and procedures for both Q Plus™ LX500
and MX500 cam brakes and Meritor automatic slack adjusters.
Do Not Lubricate the LX500 and MX500
Brakes and Automatic Slack Adjuster Before
the Specified Time or Mileage Intervals
The Q Plus™ LX500 and MX500 cam brake packages include
factory-installed Meritor automatic slack adjusters. Q Plus™ LX500
and MX500 cam brakes and slack adjusters do not require
lubrication for an extended period of time.
앫 Do not remove the identification tag that covers the grease plug.
앫 Do not grease the brake assembly or the automatic slack
adjuster prior to the specified lubrication interval times or
mileage in the table.
Inspection Procedure
1.
Check the complete air system for worn hoses and connectors.
With the air pressure at 100 psi (689 kPa), the brakes released
and the engine off, loss of tractor air pressure must not exceed
two psi (14 kPa) a minute. Total tractor and trailer loss must not
exceed three psi (21 kPa) per minute.
2.
Check to see that the air compressor drive belt is tight. Air
system pressure must rise to approximately 100 psi (689 kPa)
in two minutes.
3.
The governor must be checked and set to the specifications
supplied by the vehicle manufacturer.
4.
Both the tractor and trailer air systems must match the
specifications supplied by the vehicle manufacturer.
Every 50,000 miles (80 000 km) or every six months, whichever
comes first.
Off-Highway Linehaul Applications
At least every four months, when you replace the seals, and reline
the brakes.
Every two weeks during the first four-month period, inspect for
hardened or contaminated grease and for the absence of grease to
help determine lubrication intervals.
Lubricate more often for severe-duty applications.
88
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7 Brakes
5.
Both wheel ends of each axle must have the same linings and
drums. All four wheel ends of the tandem axles also must have
the same linings and drums. It is not necessary for the front
axle brakes to be the same as the rear driving axle brakes.
Figure 7.8.
9.
Measure the brake free stroke and adjust the chamber stroke.
10. Lubricate the brake system components.
Cam Brakes, All Models
WARNING
Figure 7.8
TANDEM AXLES
FRONT AXLE
When you perform preventive maintenance procedures on an
in-service brake, check both the free stroke and adjusted chamber
stroke.
Both wheel ends of each axle must
have identical drums and lining.
4000376a
Figure 7.8
6.
7.
8.
Before you service a spring chamber, carefully follow the
manufacturer’s instructions to compress and lock the spring to
completely release the brake. Verify that no air pressure
remains in the service chamber before you proceed. Sudden
release of compressed air can cause serious personal injury
and damage to components.
Always follow the specifications supplied by the vehicle
manufacturer for the correct lining to be used. Vehicle brake
systems must have the correct friction material and these
requirements can change from vehicle to vehicle.
The return springs must retract the shoes completely when the
brakes are released. Replace the return springs each time the
brakes are relined. The spring brakes must retract completely
when they are released.
The air chamber area multiplied by the length of the automatic
slack adjuster is called the AL factor. This number must be
equal for both ends of a single axle and all four ends of a
tandem axle. Figure 7.9.
Free stroke sets the clearance between the linings and drum. The
in-service free stroke may be slightly longer than 0.5-0.625-inch
(12.7-15.9 mm) specified in this procedure. This is not a concern if
the adjusted chamber stroke is within the limits shown in Table AW
and Table AX.
Measure Free Stroke
Before taking measurements, verify that the brakes are fully
released. Cage the spring brake chambers if equipped.
1.
Measure the distance from the center of the large clevis pin to
the bottom of the air chamber while the brake is released. The
measurement you obtain is X in Figure 7.10.
Figure 7.10
MEASURE FREE STROKE
“Y”
“X”
Figure 7.9
FREE STROKE = Y MINUS X
Drum brake free stroke must be
0.5-0.625" (12.7-15.9 mm).
Disc brake free stroke must be
0.75-0.875" (19.1-22.2 mm).
“A”
“L”
AL FACTOR = A x L
A = AIR CHAMBER AREA
L = LENGTH OF SLACK ADJUSTER
Figure 7.10
4000377a
Figure 7.9
4000372a
2.
Use a pry bar to move the slack adjuster and position the
linings against the drum with brakes applied. Measure the
same distance again while the brakes are applied. The
measurement you obtain is Y in Figure 7.10.
Meritor Maintenance Manual 1 (Revised 08-06)
89
7
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7 Brakes
CAUTION
Do not set the free stroke shorter than 0.5-0.625-inch
(12.7-15.9 mm) for drum brakes. If the measurement is too
short, linings can drag. Damage to components can result.
3.
Subtract X from Y to obtain the in-service free stroke. The
measurement must be 0.5-0.625-inch (12.7-15.9 mm) for
drum brakes. Figure 7.10.
앫 If the free stroke measurement is not within
specification: Refer to Diagnostic Charts, Table BM, in this
section.
Figure 7.11
Disengage
pull pawl
or remove
conventional
pawl.
SHORTEN
STROKE
Figure 7.11
If the brakes have spring chambers, carefully release the
springs. Test the vehicle before you return it to service.
Important Information
Meritor automatic slack adjusters (ASAs) should not need to be
manually adjusted in service. ASAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ASA,
brake actuator or other system components.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ASA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
For Meritor brake adjustment, refer to the brake adjustment tables
in this section. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
90
Measure Push Rod Travel or Adjusted Chamber
Stroke
Use the following procedure to check in-service push rod travel or
adjusted chamber stroke on truck and tractor brakes.
WARNING
Before you service a spring chamber, carefully follow the
manufacturer’s instructions to compress and lock the spring to
completely release the brake. Verify that no air pressure
remains in the service chamber before you proceed. Sudden
release of compressed air can cause serious personal injury
and damage to components.
1.
The engine must be OFF. If the brake has a spring chamber,
follow the manufacturer’s instructions to release the spring.
Verify that no air pressure remains in the service section of the
chamber.
2.
Verify that pressure is 100 psi (689 kPa) in the air tanks.
Determine the size and type of brake chambers on the vehicle.
3.
With the brakes released, mark the push rod where it exits the
chamber. Measure and record the distance. Have another
person apply and hold the brakes on full application.
Figure 7.12. Hold the ruler parallel to the push rod and
measure as carefully as possible. A measurement error can
affect CVSA re-adjustment limits. CVSA states that “any brake
1/4-inch or more past the re-adjustment limit, or any two
brakes less than 1/4-inch beyond the re-adjustment limit, will
be cause for rejection.”
LENGTHEN
STROKE
4000373a
4.
Commercial Vehicle Safety Alliance (CVSA)
Guidelines
Meritor Maintenance Manual 1 (Revised 08-06)
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7 Brakes
Table AX: Long-Stroke Clamp-Type Brake Chamber Data*
Figure 7.12
Step 1
Mark push rod here
to measure stroke.
• Spring brakes
released
• Service brakes
not applied
Step 3
Step 2
STROKE
90-100 psi (620-690 kPa)
in air tank — engine OFF
• Service brakes
applied
4000374b
Figure 7.12
Measure the push rod travel or adjusted chamber stroke from
where the push rod exits the brake chamber to your mark on
the push rod. Measure and record the distance. Figure 7.12.
5.
Subtract the measurement you recorded in Step 3 from the
measurement you recorded in Step 4. The difference is the
push rod travel or adjusted chamber stroke.
6.
Refer to Table AW or Table AX to verify that the stroke length is
correct for the size and type of air chambers on the vehicle.
앫 If the push rod travel or adjusted chamber stroke is
greater than the maximum stroke shown in Table AW
or Table AX: Refer to Diagnostic Charts, Table BM, in this
section.
Table AW: Standard-Stroke Clamp-Type Brake Chamber Data
Type
6
9
12
16
20
24
30
36
Brake
Adjustment Limit
(inches)
16
6-3/8
2.0
20
6-25/32
2.0
24
7-7/32
2.0
24
7-7/32
2.5
30
8-3/32
2.5
* For 3" maximum stroke type 24 chambers.
Alternate Method to Measure Push Rod Travel
(Adjusted Chamber Stroke)
• Spring brakes
released
4.
Type
Outside Diameter
(inches)
Outside Diameter
(inches)
4-1/2
5-1/4
5-4/16
6-3/8
6-25/32
7-7/32
8-3/32
9
Brake
Adjustment Limit
(inches)
1-1/4
1-3/8
1-3/8
1-3/4
1-3/4
1-3/4
2
2-1/4
Use the CVSA procedure, except in Steps 3-4, measure the distance
from the bottom of the air chamber to the center of the large clevis
pin on each of the brakes.
CVSA North American Out-of-Service Criteria
Reference Tables
7
Information contained in Table AW and Table AX is for reference
only. Consult the CVSA’s Out-of-Service Criteria Handbook for
North American Standards, Appendix A. Visit their website at
http://64.35.82.7/ to obtain the handbook.
Cam Brake Lubrication Intervals and
Procedures
Brake Inspections Before the Recommended
Lubrication Interval
NOTE: You do not have to replace Q Plus™ LX500 and MX500
brake camshaft bushings and seals when you reline the brake prior
to the recommended service interval.
1.
Periodically inspect brake shoe linings. If the lining thickness is
0.25-inch (6.35 mm) at the thinnest point, reline the brakes.
Refer to Maintenance Manual MM-96173, Q Plus™ LX500
and MX500 Cam Brakes, for more information. To obtain this
publication, refer to the Service Notes page on the front inside
cover of this manual.
Meritor Maintenance Manual 1 (Revised 08-06)
91
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7 Brakes
2.
Periodically inspect the brakes for correct clearance between
the lining and drum. If you must manually adjust the brakes
because of excessive air chamber stroke, correct the problem.
Refer to Maintenance Manual MM-96173, Q Plus™ LX500
and MX500 Cam Brakes, for more information. To obtain this
publication, refer to the Service Notes page on the front inside
cover of this manual.
Table AY: Q Plus™ LX500 and MX500 Cam Brake Lubrication
Intervals
Q Plus™ LX500 Cam Brake
On-Highway Linehaul
3 years/500,000 miles (805 000 km)
All Other Applications
1 year, regardless of mileage
Q, Q PLUS™ AND P SERIES
Lubricate
here only.
Lubricate
entirely.
Do not
lubricate here.
CAM
ROLLER PIN
CAM
ANCHOR PIN
4000365b
Figure 7.14
Automatic Slack Adjuster
Q Plus™ LX500 Cam Brake
On-Highway Linehaul
Figure 7.14
3 years/500,000 miles (805 000 km)
Camshaft Bushings
Inspect and lubricate the automatic slack adjuster according to one
of the schedules below. Use the schedule that requires the most
frequent inspection and lubrication, and whenever you reline the
brakes. Refer to Table BK for grease specifications.
Lubricate through the fitting on the bracket or spider until new
grease flows from the inboard seal.
앫 Vehicle manufacturer’s schedule
Rollers and Anchor Pins
앫 Every six months
When the brake is disassembled, or when necessary, lubricate the
anchor pins and rollers where these parts touch the brake shoes.
앫 A minimum of four times during the life of the linings
Do not allow the grease to contact the area of the camshaft roller
that touches the camshaft head. Figure 7.13 and Figure 7.14.
Anti-Seize Compound
Figure 7.13
15" Q AND T SERIES FRONTS
Do not
Lubricate
lubricate here.
entirely.
앫 Fleet’s schedule
Meritor lubricant specification O-637, part number 2297-U-4571,
is a corrosion-control grease. Do not mix this grease with other
greases. This compound is also available from the Southwest
Petro-Chemical Division of Witco Chemical Corporation, 1400 South
Harrison, Olathe, KS 66061, as Corrosion Control, part number
SA 8249496.
앫 Use anti-seize compound on the clevis pins of all slack adjusters.
Lubricate here only.
CAM ROLLER PIN
Figure 7.13
92
Meritor Maintenance Manual 1 (Revised 08-06)
CAM
ANCHOR PIN
4000367b
앫 Also use anti-seize compound on the automatic slack adjuster
and cam splines if the slack adjuster gear has no grease groove
and holes around its inner diameter.
mm1.fm.book Page 93 Thursday, August 24, 2006 12:29 PM
7 Brakes
Q Plus™ LX500 and MX500 Cam Brakes and
Automatic Slack Adjusters After the
Specified Time or Mileage Intervals
Brakes Without a Pressure Relief Valve Built Prior to
July 2000
1.
Remove the identification tag from the chamber bracket.
2.
Remove the grease plugs from both the chamber bracket and
the automatic slack adjuster.
6.
Replace the grease fittings with grease plugs. Cover the
bracket plug with a new identification tag.
7.
After the first lubrication, follow the manufacturer’s chassis
lubrication schedule and your regular preventive maintenance
schedule. You should also continue to perform periodic
inspections of the brakes.
Cam Brake Tips
Air Chambers
3.
Remove the automatic slack adjuster. Remove the O-ring from
the splined gear. Discard the O-ring. Install the automatic slack
adjuster onto the camshaft.
To ensure correct brake balance, all brake chambers on the same
axle must be the same size and type to help ensure a balanced
brake system for maximum lining wear and drum life.
4.
Install the grease fittings. Use Meritor-approved synthetic
grease O-695 NLGI Grade 2 to lubricate the brake assembly
through the grease fitting in the bracket until new grease flows
from the inboard, slack end, seal.
Brake Kits
5.
Use Meritor-approved synthetic grease O-695 to lubricate the
automatic slack adjuster through the grease fitting until new
grease purges out of the pull pawl.
6.
Replace the grease fittings with grease plugs. Cover the
bracket plug with a new identification tag.
7.
After the first lubrication, follow the manufacturer’s chassis
lubrication schedule and your regular preventive maintenance
schedule. You should also continue to perform periodic
inspections of the brakes.
Brakes with a Pressure Relief Valve Built After
July 2000
1.
Remove the identification tag from the chamber bracket.
2.
Remove the grease plugs from both the chamber bracket and
the automatic slack adjuster.
3.
Remove the automatic slack adjuster. Remove the O-ring from
the splined gear. Discard the O-ring. Install the automatic slack
adjuster onto the camshaft.
4.
5.
Install the grease fittings. Use Meritor-approved synthetic
grease O-695 NLGI Grade 2 to lubricate the brake assembly
through the grease fitting in the bracket until new grease flows
from the pressure relief valve in the bracket.
Use Meritor-approved synthetic grease O-695 to lubricate the
automatic slack adjuster through the grease fitting until new
grease purges out of the pull pawl.
Meritor brake shoes, rollers, camshafts and shoe return springs are
designed to perform as a system. Always install original equipment
manufacturer’s components during maintenance or when you
upgrade from standard to long-life brakes to help ensure correct
brake performance and maximum lining life.
7
Cam Heads
Cam heads can look the same, but that doesn’t mean they will
perform the same in your brake system. Two cam head profiles can
appear to be identical, but very small differences in the cams from
different manufacturers can be significant enough to affect the
performance of your brakes. To ensure a balanced brake system
and optimum lining and drum life, always install the correct
replacement cam.
Cam Rollers
To avoid flat spots, lubricate a cam roller directly in the web roller
pocket and not at the cam-to-roller contact area. Flat spots can
affect brake adjustment and result in premature brake wear or
reduced braking performance.
Drums
To help ensure balanced braking, even lining and drum wear, and
correct function of the automatic slack adjuster, do not install a cast
drum and a centrifuse drum on the same axle.
A cast drum and a centrifuse drum each absorbs and dissipates
heat differently. When drum types and weights are mixed, different
rates of heat absorption and dissipation occur that can affect the
brake system.
Meritor Maintenance Manual 1 (Revised 08-06)
93
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7 Brakes
Hardware
Trailer Cam Brakes
When you service cam brakes, replace all the springs, anchor pins,
bushings and rollers — not just the shoe return springs — to help
ensure maximum braking performance.
Long-life bushings require correct lubrication for maximum
performance and bushing life. Although you do not have to replace
spider cam bushings on trailer axles as frequently, Meritor
recommends that you lubricate the bushings at least four times
during the life of your brake lining.
Linings
Insist on the same brand of quality friction lining material
recommended by the component equipment manufacturer to help
ensure fewer relines and compatibility with your present system.
Replacement Parts
Always use the component equipment manufacturer recommended
quality standard parts. Meritor brakes work as a system, and when
you replace original parts with “will-fit” parts, you can compromise
the performance of the entire system.
Return Springs
Automatic Slack Adjusters
Automatic doesn’t mean maintenance-free. Correctly-installed and
lubricated automatic slack adjusters help to ensure maximum brake
system performance.
Never mix automatic slack adjusters on the same axle. When you
replace automatic slack adjusters, always use the replacement parts
that were originally designed for the brake system to help ensure
even brake wear, balanced braking and maximum brake
performance.
Replace cam brake return springs at every cam brake reline. The
return spring is critical to alignment, accurate return of the brake
away from the drum and correct automatic slack adjustment.
Approved Lubricants
Table AZ: Cam Brake Grease Specifications
Components
Meritor Specification
NLGI Grade
Grease Type
Outside Temperature
Retainer Clips
O-616-A
1
Clay Base
Down to −40° F (−40° C)
Anchor Pins
O-617-A
1
Rollers, Journals Only
O-617-B
2
Lithium 12-Hydroxy
Stearate or Lithium
Complex
Refer to the grease
manufacturer’s specifications
for the temperature service
limits.
O-645
2
Synthetic Oil, Clay Base
Down to −65° F (−54° C)
O-692
1 and 2
Lithium Base
Down to −40° F (−40° C)
Any of Above
Refer to Above
Refer to Above
Refer to Above
O-637*
1-1/2
Calcium Base
O-641
—
Anti-Seize
Refer to the grease
manufacturer’s specifications
for the temperature service
limits.
Camshaft Bushings
Camshaft Splines
* Do not mix Meritor grease specification O-637, part number 2297-U-4571, a calcium-base, rust-preventive grease, with other greases.
94
Meritor Maintenance Manual 1 (Revised 08-06)
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7 Brakes
Table BA: Approved Greases for Q Plus™ LX500 and MX500
Lubricant
Recommendation
O-617-A
O-617-B
Multi-Purpose Lithium Chassis Grease
O-645
Mobilgrease 28 (Military)
Mobiltemp SHC 32 (Industrial)
Aerospace Lubricants Inc. Tribolube 12-Grade 1
O-692
Amoco Super Permalube™ Grade 2
Citgo Premium Lithium EP-2 Grade 2
Exxon Ronex MP-2 Grade 2
Kendall L-427 Super Blu Grade 2
Mobilith AW-1 Grade 1
Sohio Factran EP-2 Grade 2
O-695
ECL (Engineered Custom Lubricants) EvoLube
TEK664
Table BB: Q Plus™ LX500 and MX500 Greasing Specifications
7
Meritor
Specification
NLGI Grade
Grease Description
Outside Temperature
Camshaft Splines and Clevis
Pins
O-695
2
Synthetic Polyurea
−40° F (−40° C)
Anchor Pins
O-617-A
1
When the brake is
disassembled, or when
necessary, lubricate the anchor
pins where they touch the
brake shoes.
or
Lithium 12-Hydroxy
Stearate or Lithium
Complex
Refer to the grease
manufacturer’s
specifications for the
temperature service limits.
Component
O-617-B
2
O-645
2
Synthetic Oil, Clay
Base
Down to −65° F (−54° C)
O-692
1 and 2
Lithium Base
Down to −40° F (−40° C)
Shoe Rollers
O-617-A
1
When the brake is
disassembled, or when
necessary, lubricate the rollers
where they touch the brake
shoes. DO NOT get grease on
the part of the roller that
touches the cam head.
or
O-617-B
2
Lithium 12-Hydroxy
Stearate or Lithium
Complex
Refer to the grease
manufacturer’s
specifications for the
temperature service limits.
Automatic Slack Adjusters
O-695
2
Synthetic Polyurea
−40° F (−40° C)
Meritor Maintenance Manual 1 (Revised 08-06)
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7 Brakes
Important Information
Meritor automatic slack adjusters (ASAs) should not need to be
manually adjusted in service. ASAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ASA,
brake actuator or other system components.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ASA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
For Meritor brake adjustment, refer to the brake adjustment tables
in this section. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
Cam Brake Troubleshooting
Diagnostic Charts
Table BC: Cam Brake, All Models
Symptoms
Adjusted stroke is too long
Possible Causes
Incorrect slack adjuster part number
No adjustment
Clevis installed at the incorrect angle
Excessive wear between the clevis and collar,
more than 0.060-inch (1.52 mm)
Loose jam nut at clevis
Worn clevis pin bushing in slack arm, inside
diameter larger than 0.53-inch (13.46 mm)
Weak or broken return spring in air chamber,
spring force must be at least 32 lb
(142.4 N폷m) at first push rod movement
Spring brake does not retract fully
Worn or stripped teeth on pawl or actuator
High torque is required to rotate the worm
when slack is removed from vehicle
Corrective Actions
Check with the warehouse distributor or original
equipment manufacturer.
Use the correct template or BSAP setting to install the
clevis correctly.
Replace with a threaded clevis.
Tighten to specification.
Replace the bushing.
Replace the return spring or air chamber.
Repair or replace the spring brake.
Replace the slack adjuster.
Replace the slack adjuster.
앫 In service slack, maximum worm torque:
45 lb-in (5.09 N폷m)
앫 New or rebuilt slack, maximum worm
torque: 25 lb-in (2.83 N폷m)
Excessive looseness between camshaft
splines and automatic slack adjuster gear
Worn components, cam bushing, for example,
in the foundation brake
96
Meritor Maintenance Manual 1 (Revised 08-06)
Replace the powershaft, gear or automatic slack
adjuster as needed.
Replace the components.
mm1.fm.book Page 97 Thursday, August 24, 2006 12:29 PM
7 Brakes
Table BC: Cam Brake, All Models
Symptoms
Adjusted stroke is too
short
Linings drag
Possible Causes
Non-original equipment manufacturer
replacement linings with excessive swell or
growth
Incorrect slack adjuster part number
Clevis installed at the incorrect angle
Loose jam nut at clevis
Spring brake does not retract fully
Incorrect manual adjustment
Poor contact between linings and drum, or
drum is out-of-round
Brake temperature imbalance
Air Disc Brakes
Corrective Actions
Use Meritor-approved linings.
Check with the warehouse distributor or original
equipment manufacturer.
Use the correct template to install the clevis correctly.
Tighten to specification.
Repair or replace the spring brake.
Adjust the brake.
Repair or replace the drums or linings.
Correct the brake balance.
When you release the brakes, the piston return spring retracts the
piston, which forces the camshaft nut back into its starting position,
and releases the clamping force of the disc.
Technical Publications
How to Obtain Additional Maintenance and Service
Information
Figure 7.15
DISC, ROTOR —
VENTED TYPE
7
CALIPER
AUTOMATIC
SLACK
ADJUSTER
Refer to the publications in Table BD. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
Table BD: Publications
INBOARD
OUTBOARD
Model
Manual
ADB Series Air Disc Brakes
Maintenance Manual 4M
Air Disc Brakes
Failure Analysis Manual
TP-0445
OUTBOARD SHOE
AND LINING PAD
PISTON
RETURN
SPRING
NUT
POWER
SHAFT
BRAKE PISTON
INBOARD SHOE AND LINING PAD
Description
4001535a
Figure 7.15
How an Air Disc Brake Functions
When you apply the brakes, the air chamber push rod pushes the
automatic slack adjuster mounted to the camshaft, which rotates
the camshaft and causes the camshaft nut to slide outward along
the camshaft. Figure 7.15.
The camshaft nut moves the piston and the inboard lining against
the disc, and this force pulls the caliper inward along the slide pins.
The caliper movement enables the outboard pad to contact the disc,
which results in a clamping force on both sides of the disc.
Features
Dura-Master® Model ADB 1560
앫 An easily-visible indicator to detect lining wear
앫 A caliper that pivots away from the disc for quick shoe and lining
changes
앫 Meritor automatic slack adjuster
앫 A caliper that’s sealed and lubricated to protect components that
actuate the brake
앫 Standard-service air chambers, or air chambers with springs
Meritor Maintenance Manual 1 (Revised 08-06)
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7 Brakes
DiscPlus™ DX195 and DX225 Air Disc Brakes
Identification
DX195 and DX225 air disc brakes are optional on FF and FG front
steer axles. Brakes feature sealed calipers lubricated to protect
components that actuate the brake. The brake is comprised of a
lightweight single-piece cast caliper supported on twin fully seated
slide pins fixed to a mounting saddle. Figure 7.16.
Dura-Master® ADB 1560 Air Disc Brake
앫 A model number tag is attached to the grease fitting on the
brake caliper assembly.
앫 An example of a part number format for an ADB 1560 brake is
ADB 1560 1234.
Figure 7.16
DiscPlus™ Air Disc Brake
앫 A model number tag is attached to the top surface of the caliper.
앫 An example of a part number format for a DiscPlus™ brake is
DX 195 1234.
Model Nomenclature
Refer to Figure 7.17 and Figure 7.18 for an explanation of model
numbers.
4002891a
Figure 7.16
Figure 7.17
DiscPlus™ Air Disc Brakes
Model Numbers and Designations
D X
DiscPlus™
195
1234
Wheel Size (Inches)
195 = 19.5"
225 = 22.5"
Specification Number
4002716b
Figure 7.17
Figure 7.18
Dura-Master ® Air Disc Brakes
Model Numbers and Designations
ADB
15
60
1234
Air Disc Brake
Design
Rotor Diameter
(Inches)
Lining Area
(Sq Inches)
Specification Number
K
Optional Subscript
K = With Torque
Plate and Slide Pins
4002716d
Figure 7.18
98
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7 Brakes
Air Disc Brake Inspection Intervals and
Procedures
Slide Pins and Bushings: Air Disc Brake Model
ADB 1560
1.
Check for contamination on the slide pins. If necessary, remove
and clean the slide pins and caliper bushings.
2.
Use a pin gauge J-34064-54, to check the slide pin bushings
for wear. If you can fit the gauge between the slide pin and the
bushing, the bushing or slide pin is worn. Replace worn
bushings and slide pins. To obtain the pin gauge, contact SPX
Kent-Moore at 800-328-6657.
Inspection Schedules
Use the schedule below that gives the most frequent inspection.
앫 Fleet chassis lubrication schedule
앫 Chassis manufacturer lubrication schedule
앫 At least four times during the lining life
앫 At tire replacement
Rotors
Minor Inspections
Inspect the rotor for cracks, deep scores or other damage. Replace
the rotor when necessary.
The maintenance schedules shown in this manual are for normal
operating conditions. Refer below for other operating conditions.
앫 Operation under severe conditions can require shorter periods
between maintenance.
앫 Operation over long distances with few stops can permit longer
periods between maintenance.
A maintenance schedule for each vehicle can be set after the brakes
are inspected several times.
Major Inspections
Inspect and lubricate the brake and automatic slack adjuster
according to one of the following schedules. Use the schedule that
provides the most frequent inspection and lubrication.
Air Chamber
Move the air chamber from side-to-side to check that the caliper
moves freely on the slide pins. When the caliper does not move freely,
inspect the slide pins, slide pin bushings and slide pin retainers for
wear or damage. Replace components when necessary.
Linings
7
When the linings wear, the caliper slides in along the slide pins.
To check for lining wear, check the position of the caliper inboard
bosses on the slide pins. Figure 7.19. If the bosses are within
0.25-inch (6.4 mm) of the ends of the pins, remove the wheels and
tires and inspect the linings. If the bosses are within 0.125-inch
(3.2 mm) of the ends of the pins, replace the linings.
앫 The chassis lubrication schedule used by your fleet.
앫 The chassis lubrication schedule recommended by the chassis
manufacturer.
앫 A minimum of four times during the life of the linings.
Figure 7.19
CALIPER
INBOARD
BOSS
Check when 1/4" (6.4 mm).
Replace when 1/8" (3.2 mm).
SLIDE PIN
Air System
CALIPER MOVES INWARD
앫 A vehicle equipped with a combination of air disc and drum
brakes requires special attention to obtain maximum brake
performance.
앫 Replace the air system valves with valves of identical
performance characteristics.
UNWORN
앫 A correctly maintained air system and correct air pressure to
each brake can help to ensure maximum brake performance and
reduced lining wear.
WORN
Automatic Slack Adjusters
Refer to Automatic Slack Adjusters in this section.
LINING WEAR INDICATOR
4001655a
Figure 7.19
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7 Brakes
Major Inspections
2.
When you reline the brakes, or at least one time a year, perform the
following inspection.
Verify that pressure is 100 psi (689 kPa) in the air tanks.
Determine the size and type of brake chambers on the vehicle.
3.
With the brakes released, mark the push rod where it exits the
chamber. Measure and record the distance. Have another
person apply and hold the brakes on full application.
Figure 7.20. Hold the ruler parallel to the push rod and
measure as carefully as possible. A measurement error can
affect CVSA re-adjustment limits. CVSA states that “any brake
1/4-inch or more past the re-adjustment limit, or any two
brakes less than 1/4-inch beyond the re-adjustment limit, will
be cause for rejection.”
1.
Inspect the automatic slack adjuster and brakes as previously
described in Minor Inspections. Perform minor inspections
before you do any other maintenance or reline procedures.
2.
Perform all the procedures, inspections and measurements.
3.
Lubricate the automatic slack adjuster and the caliper.
4.
Adjust the brakes.
Important Information
Figure 7.20
Meritor automatic slack adjusters (ASAs) should not need to be
manually adjusted in service. ASAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ASA,
brake actuator or other system components.
Step 1
• Spring brakes
released
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
• Service brakes
not applied
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ASA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
Step 3
Use the following procedure to check in-service push rod travel or
adjusted chamber stroke on Meritor air disc brake Model ADB 1560.
1.
100
The engine must be OFF. If the brake has a spring chamber,
follow the manufacturer’s instructions to release the spring.
Verify that no air pressure remains in the service section of the
chamber.
Meritor Maintenance Manual 1 (Revised 08-06)
STROKE
• Spring brakes
released
• Service brakes
applied
4000374b
Figure 7.20
4.
Measure the push rod travel or adjusted chamber stroke from
where the push rod exits the brake chamber to your mark on
the push rod. Measure and record the distance. Figure 7.20.
5.
Subtract the measurement you recorded in Step 3 from the
measurement you recorded in Step 4. The difference is the
push rod travel or adjusted chamber stroke.
6.
Refer to Table BE or Table BF to verify that the stroke length is
correct for the size and type of air chambers on the vehicle.
WARNING
Before you service a spring chamber, carefully follow the
manufacturer’s instructions to compress and lock the spring to
completely release the brake. Verify that no air pressure
remains in the service chamber before you proceed. Sudden
release of compressed air can cause serious personal injury
and damage to components.
Step 2
90-100 psi (620-690 kPa)
in air tank — engine OFF
For Meritor brake adjustment, refer to the brake adjustment tables
in this section. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
Commercial Vehicle Safety Alliance (CVSA)
Guidelines
Mark push rod here
to measure stroke.
앫 If the adjusted chamber stroke is greater than the
maximum stroke shown in Table BE or Table BF: Refer
to Brake Diagnostic Charts, Table BH, in this section.
mm1.fm.book Page 101 Thursday, August 24, 2006 12:29 PM
7 Brakes
Table BE: Standard-Stroke Clamp-Type Brake Chamber Data
Type
Outside Diameter
(inches)
Brake
Adjustment Limit
(inches)
6
4-1/2
1-1/4
9
5-1/4
1-3/8
12
5-4/16
1-3/8
16
6-3/8
1-3/4
20
6-25/32
1-3/4
24
7-7/32
1-3/4
30
8-3/32
2
36
9
2-1/4
Table BF: Long-Stroke Clamp-Type Brake Chamber Data
Type
Outside Diameter
(inches)
Brake
Adjustment Limit
(inches)
16
6-3/8
2.0
20
6-25/32
2.0
24
7-7/32
2.0
24*
7-7/32
2.5
30
8-3/32
2.5
* For 3" maximum stroke type 24 chambers.
Important Information
Meritor automatic brake adjusters (ABAs) should not need to be
manually adjusted in service. ABAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ABA,
brake actuator or other system components.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ABA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
For Meritor brake adjustment, refer to the brake adjustment tables
in this section. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
Checking the Adjusted Chamber Stroke
Length on DiscPlus™ DX195 and DX225 Air
Disc Brakes
Use the following procedures to check in-service push rod travel.
1.
The engine must be off.
2.
Check the gauges in the cab to ensure that the air pressure in
the tanks is between 90-100 psi (620-689 kPa).
3.
Measure the distance from the bottom of the air chamber to
the center of the clevis pin while the brakes are released.
Figure 7.21.
Alternate Method to Measure Push Rod Travel
(Adjusted Chamber Stroke)
Use the CVSA procedure, except in Steps 3-4, measure the distance
from the bottom of the air chamber to the center of the large clevis
pin on each of the brakes.
Figure 7.21
MEASURE ADJUSTED CHAMBER STROKE
CVSA North American Out-of-Service Criteria
Reference Tables
Information contained in Table BE and Table BF is for reference only.
Consult the CVSA’s Out-of-Service Criteria Handbook for North
American Standards, Appendix A. Visit their website at
http://64.35.82.7/ to obtain the handbook.
Measure
this
distance.
4002890a
Figure 7.21
Meritor Maintenance Manual 1 (Revised 08-06)
101
7
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7 Brakes
4.
Have another person apply and hold the brakes on full
application.
5.
Measure the distance from the bottom of the air chamber to
the center of the clevis pin while the brakes are applied.
6.
To determine push rod travel, adjusted chamber stroke:
Subtract the measurement you obtained in Step 2 from the
measurement you obtained in Step 5. The difference is the
push rod travel, adjusted chamber stroke.
A.
Push rod travel, adjusted chamber stroke, must not be
greater than two-inches (50.8 mm) for the type 16 and
20 long-stroke chambers used on these axles.
B.
If push rod travel, adjusted chamber stroke, is greater
than the maximum stroke, refer to Condition 1 in Table BI
for more information.
DiscPlus™ DX195 and DX225 Air Disc Brake
Components
Lining Thickness
Lining material thickness must not be less than 0.200-inch
(5.1 mm). Replace the linings before the lining material thickness
reaches this specification.
Anti-Rattle Springs
1.
Anti-rattle springs are attached to the linings. Inspect for bent,
cracked or broken springs.
2.
If you find damaged springs, replace the springs.
Seals
Replace the caliper if you find cracked, torn or otherwise
damaged seals.
Caliper
The caliper should slide freely on the slide pins. Slide the caliper
back and forth to check for clearance between the disc, rotor,
and pad.
Disc and Rotor
CAUTION
Always replace a cracked disc to avoid serious personal injury
and damage to components.
Inspect both sides of the disc, rotor, for the following conditions.
Replace the disc, rotor, if necessary.
앫 When a crack extends through a section of the disc, rotor,
replace the disc, rotor.
앫 Heat checks are short, thin, sometimes numerous radial
interruptions of the braking surfaces of the rotor. They are a
normal phenomena of the disc brake function. They are the
result of the heating and cooling that occurs as brakes are
applied time after time. Heat checks will frequently wear away
and reform or they may progress into braking surface cracks,
depending on such factors as the lining/rotor wear rate, brake
balance and how hard the brakes are used. There are two kinds
of heat checking: light and heavy.
앫 Cracks on the surface of the disc, rotor, that result from light
heat checking are small and fine and do not require disc, rotor,
replacement.
앫 Heavy heat checking is surface cracks that have width and
depth. If you find heavy heat checking, replace the disc, rotor.
앫 Inspect both sides of the disc, rotor. If you find deep grooves or
scores, replace the disc, rotor. If the grooves or scores are not
too deep, you can continue to use the disc.
앫 Blue marks or bands indicate that the disc, rotor, was very hot.
Refer to Conditions 2, 3 and 4 in Table BI to determine the cause
and correct the condition.
앫 Measure the thickness of the disc, rotor, when you reline the
brakes. The disc, rotor, must be at least 1.626-inches
(41.3 mm). Figure 7.22. If the thickness of a disc, rotor, is less
than the specification, replace the disc, rotor.
Figure 7.22
1.626" (41.3 MM)
MINIMUM THICKNESS
VENTED DISC
4002908a
Figure 7.22
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7 Brakes
Air Disc Brake Model ADB 1560
Lubrication Intervals and Procedures
Figure 7.23
MANUFACTURED BEFORE 1985
RELIEF VALVE
GREASE FITTING
Lubrication Procedures
CAUTION
Do not use lithium-based grease inside the caliper.
Lithium-based grease may not adequately lubricate the
caliper. Damage to the caliper can result. Some lithium-based
greases can be used in the automatic slack adjuster. Refer to
the approved lithium-based greases for automatic slack
adjusters.
Lubricate the Automatic Slack Adjuster
4001650a
Figure 7.23
Figure 7.24
MANUFACTURED FROM 1985 TO 1991
Use a grease gun to lubricate the automatic slack adjuster through
the grease fitting until new grease flows from the pressure relief
seal under the pawl assembly.
RELIEF VALVE
GREASE FITTING
Anti-Seize Compound
Meritor lubricant specification O-637, part number 2297-U-4571,
is a corrosion-control grease. Do not mix this grease with other
greases. This compound is also available from the Southwest
Petro-Chemical Division of Witco Chemical Corporation, 1400 South
Harrison, Olathe, KS 66061, as Corrosion Control, part number
SA 8249496.
7
4001651a
Figure 7.24
Figure 7.25
앫 Use anti-seize compound on the clevis pins of all slack adjusters.
MANUFACTURED AFTER 1991
GREASE FITTING
Also use anti-seize compound on the automatic slack adjuster
and cam splines if the slack adjuster gear has no grease groove
and holes around its inner diameter.
Lubricate the Caliper
CAUTION
Only use Meritor specification O-616-A or O-645 grease inside
the disc brake caliper. Do not use lithium-base grease, which
can melt from high temperatures inside the caliper. Damage to
components can result.
RELIEF
VALVE
4001652a
Figure 7.25
Meritor air disc brakes have been manufactured in three designs.
Note that the location of the caliper grease fitting and pressure relief
valve is different in brakes manufactured before 1985, from 1985 to
1991, and after 1992. Figure 7.23, Figure 7.24 and Figure 7.25.
Meritor Maintenance Manual 1 (Revised 08-06)
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7 Brakes
Lubricate brake-actuating components inside the caliper two to four
times during the life of the lining, or every six months.
1.
Turn the adjusting nut on the automatic slack adjuster to move
the inboard lining against the rotor. Figure 7.26.
NOTE: For calipers with grease fittings in the caliper and the
camshaft cap, first apply grease to the caliper fitting, then apply
grease to the camshaft cap fitting.
3.
Apply grease through the grease fitting in the caliper until
grease flows out of the seal at the camshaft cap.
Figure 7.26
CAUTION
You must force excess grease from the caliper. Brakes can
drag due to excessive grease in the caliper, which will reduce
brake lining life.
4.
Remove the pressure relief valve from the caliper. Turn the
slack adjuster adjusting nut in the opposite direction to fully
retract the caliper piston and force the excess grease through
the pressure relief hole.
5.
Clean the excess grease from the outside of the caliper with
a rag.
6.
Install the pressure relief valve.
7.
Adjust the brake.
STEP 1
STEP 2
4001653a
Figure 7.26
2.
Plug the pressure relief valve by holding a finger over the
poppet.
Approved Lubricants
Table BG: Air Disc Brake Model ADB 1560 Grease Specifications
Component
1
Caliper
Slide Pin Retainers
Powershaft Splines
1
2
Meritor
Specification
NLGI Grade
Grease Description
Outside Temperature
O-616-A
1
Clay Base
Down to −40° F (−40° C)
O-645
2
Synthetic Oil, Clay
Base
Down to −65° F (−54° C)
O-6372
1-1/2
Calcium Base
O-641
—
Anti-Seize
Refer to the grease
manufacturer’s specifications for
the temperature service limits.
Any of Above
Refer to Above
Refer to Above
Refer to Above
The grease used inside the caliper must be non-melting and also allow correct brake function at cold temperatures listed.
Do not mix O-637 calcium-base, corrosion-control grease with other greases.
104
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7 Brakes
Important Information
Meritor automatic slack adjusters (ASAs) should not need to be
manually adjusted in service. ASAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ASA,
brake actuator or other system components.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ASA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
For Meritor brake adjustment, refer to the brake adjustment tables
in this section. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
Air Disc Brake Troubleshooting
Brake Diagnostic Charts
Table BH: Air Disc Brake
Conditions
Poor stopping power
앫 Long stopping
distances
앫 Poor driver feel
앫 High brake pressures
Possible Causes
Incorrect air chamber or
slack adjuster size
Vehicle air system
malfunction
Brakes out-of-adjustment
Check For
Check with vehicle manufacturer or
Meritor for correct chamber and
slack adjuster size.
Correct air pressure at the chamber
inlet
Stroke
Corrections
Replace equipment with the
recommended size.
Installation with auto slack template
Adjust to the recommended stroke.
Jam nut torque
Correct the set-up and check with the
template.
Clevis wear
Vehicle overload
Poor grade holding
ability
앫 Vehicle does not hold
on typical grade
Brake not functioning
앫 Lack of normal
response
Contamination on the
linings
Companion vehicle brakes
not working correctly
Refer to Poor stopping
power
Incorrect spring brake
chamber size
Spring brake power spring
in the caged position
Refer to Poor stopping
power
Internal caliper failure
Have the air system evaluated by a
qualified brake system specialist.
Repair, replace parts as required.
Pawl wear
Overloading — see GAWR
limitations on vehicle I.D. plate.
Grease, oil, etc., on the linings
Tighten as required.
Inspect the companion vehicle
brakes and air system.
—
Adjust or repair as required.
7
Observe the vehicle manufacturer’s
load recommendations.
Replace the linings.
As required. Refer to Poor stopping
power.
Replace with the correct chamber as
required.
Check with original equipment
manufacturer or Meritor for the
correct size.
—
Uncage the power spring.
—
Movement of the load plate piston
when actuating the automatic slack
adjuster
As required. Refer to Poor stopping
power.
Disassemble and overhaul the
caliper.
Meritor Maintenance Manual 1 (Revised 08-06)
105
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7 Brakes
Table BH: Air Disc Brake
Conditions
Vehicle pulls to one side
when stopping
Brake drag
앫 Evidence of severe
heat
앫 Rapid lining wear
앫 Heavy blueing or
discoloration of disc
or rotor braking
surface
Possible Causes
Refer to Poor stopping
power, Poor grade holding
ability and Brake not
functioning.
Incorrect manual
adjustment
Vehicle air system
malfunction
Spring brake not releasing
Excessive grease pressure
in the caliper
Internal corrosion of
caliper assembly
앫 Brake drag
Caliper seized on slide
pins
Misalignment of slide pins
106
Corrections
Refer to Poor stopping power, Poor
grade holding ability and Brake not
functioning.
Automatic slack adjuster set-up
Correct running clearance
pad-to-disc or rotor
Correct operation of the quick
release valve and relay valve
Vehicle air system leakage
Correct the set-up. Adjust to the
recommended stroke and running
clearance. Check with the template.
Spring brake chamber malfunction
앫 Torn or charred
piston or caliper boot
seal
Short outboard lining life
Check For
—
Meritor Maintenance Manual 1 (Revised 08-06)
Slow build-up of trailer emergency
air pressure
Incorrect air pressure range at
compressor or governor
Incorrect lubrication procedures
Piston boot and caliper seals
Excessive paint or other foreign
build-up on the caliper slide pins or
bushings
Caliper should move back and forth
with hand effort, 20-30 lb-ft
(27-41 N폷m)
Repair or replace parts as required.
Find the source of the leak and repair
as required.
Repair or replace the spring brake
chamber as required.
Wait for full build-up before driving.
Set the compressor or governor to
the correct pressure range.
Follow the lubrication
recommendations.
Replace the seals as required.
Inspect and overhaul the caliper
assembly as required.
Remove both pins. Clean, inspect
and replace the pins and bushings as
required.
Remove the pads. Clean, inspect and
replace the slide pins and bushings
as necessary. Install the caliper and
slide pins without the pads. Tighten
the retainer nuts. Check that the
caliper slides freely on the slide pins.
If the problem continues, check the
axle mounting flange for nicks, burrs
or gouges. Repair as necessary.
Install the torque plate and caliper
and check again for free movement.
If the flange is acceptable but the
problem continues, contact your
Meritor representative for
information.
mm1.fm.book Page 107 Thursday, August 24, 2006 12:29 PM
7 Brakes
Table BH: Air Disc Brake
Conditions
Short lining life
Pad backing plate tab
wear
Fractured disc or rotor
앫 Cracked or broken
Slide pin or retainer pin
assemblies hard to
remove
Brake smoking
Possible Causes
Refer to Brake drag and
Short outboard lining life.
Abusive use of brake
system
Vehicle overload
Companion vehicle brakes
do not work correctly
Brinnelling of pad tab area
Refer to Brake drag, Short
outboard lining life and
Short lining life.
Failure to perform routine
checks on lining wear and
caliper position on slide
pins
Highly corrosive
environment
Check For
—
Corrections
Refer to Brake drag and Short
outboard lining life.
Train the drivers.
Driver technique
Overloading. Refer to gross axle
weight ratings (GAWR) limitations on
vehicle identification plate.
Inspect companion vehicle brakes
and air system.
Signs of brinnelling and
back-and-forth movement of the pad
in the caliper
—
Disc or rotor for minimum thickness
Observe the vehicle manufacturer’s
load recommendations.
Adjust or repair as required.
Remove and replace the pads. Check
the anti-rattle clip. If wear is
excessive, replace the caliper
assembly.
Replace the disc or rotor, shoes and
linings as required. Review the
correct maintenance procedures with
personnel.
7
Signs of corrosion
Inspect the slide pins and retainer pin
assemblies. Replace as required.
Apply an anti-seize compound to the
retainer, but not to the threads.
Leaking hub or wheel seal
Condition of seals
Leaking caliper sealing
components
Piston boot popped out of
piston seating groove
Condition of piston boot, piston cap
seal and piston or caliper seal
Excessive lubrication of caliper.
Inspect piston boot position.
Paint on slide pins or
brake
High brake temperature
All painted surfaces
Refer to Poor stopping power, Brake
drag, Short outboard lining life and
Short lining life.
Seal the inner end of the lower slide
pin retainer hole in the torque plate.
Replace as required. Clean the disc
or rotor as required. Inspect the pads
and replace if oil-soaked.
Replace as required.
Follow the lubrication
recommendation. Replace the piston
boot if required.
Clean the slide pins and brake as
required.
Refer to Poor stopping power, Brake
drag, Short outboard lining life and
Short lining life.
Meritor Maintenance Manual 1 (Revised 08-06)
107
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7 Brakes
Important Information
Meritor automatic brake adjusters (ABAs) should not need to be
manually adjusted in service. ABAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ABA,
brake actuator or other system components.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ABA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
For Meritor brake adjustment, refer to the brake adjustment tables
in this section. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
DiscPlus™ DX195 and DX225 Air Disc Brakes
Table BI: DiscPlus™ DX195 and DX225 Air Disc Brakes
Condition
Possible Causes
Check For
Actions Required
1 — Air chamber exceeds
2-inch maximum
stroke requirement at
90-100 psi
(620-689 kPa) in cab
Incorrect initial
adjustment or inoperative
automatic adjuster
Recheck chamber stroke
after 20 brake
applications.
If the air chamber still overstrokes, then replace
the caliper/saddle assembly.
2 — Brake drag
Incorrect lining-to-rotor
clearance
Replace the caliper/saddle assembly.
Incorrect initial
adjustment
Minimum stroke at
90-100 psi
(620-689 kPa) in cab to
be 7/8-inch (22 mm)
Vehicle air system
malfunction
Correct operation of quick
release valve
Repair or replace the parts as required.
3 — Short outboard brake
pad lining life
Caliper seized or sticking
on slide pins
Damaged slide-pin seals.
Repair the caliper/saddle assembly.
4 — Short lining life
Refer to conditions 2
and 3.
Refer to conditions 2
and 3.
Refer to conditions 2 and 3.
Rotor surface
Cracks or heavy heat
checking. Refer to
condition 3.
Refer to conditions 3 and 4 for disc, rotor,
inspection.
Vehicle overload
Refer to GAWR limitations
on vehicle I.D. plate.
Observe the vehicle manufacturer’s load
recommendations.
Companion brakes not
working correctly.
Inspect companion
vehicle brakes and air
system.
Adjust or repair as required.
High brake temperature
Refer to conditions 2, 3
and 4.
Refer to conditions 2, 3 and 4.
Contamination on linings
Grease, oil, etc., on
linings
Inspect the hub seal. Replace as required. Clean
the rotor and caliper assembly. Replace linings.
5 — Brake smoking
108
Meritor Maintenance Manual 1 (Revised 08-06)
Readjust the rotor-to-pad clearance.
Caliper should move
back-and-forth by hand
with linings removed.
mm1.fm.book Page 109 Thursday, August 24, 2006 12:29 PM
7 Brakes
Table BI: DiscPlus™ DX195 and DX225 Air Disc Brakes
Condition
Possible Causes
Check For
Actions Required
6 — Poor stopping power
Vehicle air systems
malfunction
Correct air pressure at
the chamber inlet
Have the air system evaluated by a qualified
brake system specialist.
Brakes out of adjustment
Stroke exceeds 2-inch
requirement.
Refer to condition 1.
앫 High brake pressures
Vehicle overload
앫 Lack of normal
response
Refer to GAWR limitations
on vehicle I.D. plate.
Observe the vehicle manufacturer’s load
recommendations.
Contamination on linings
Grease, oil, etc., on
linings
Observe the vehicle manufacturer’s load
recommendations.
Companion brakes not
working correctly
Inspect companion
vehicle brakes and air
system.
Adjust or repair as required.
Refer to conditions 1, 2
and 6.
Refer to conditions 1, 2
and 6.
Refer to conditions 1, 2 and 6.
앫 Long stopping
distances
앫 Poor driver feel
앫 Vehicle pulls to one
side
7 — Shimmy or brake pull
Rotor runout and
thickness variation
Replace the hub and rotor assembly.
Automatic Slack Adjusters
Technical Publications
Important Information
How to Obtain Additional Maintenance and Service
Information
Meritor automatic slack adjusters (ASAs) should not need to be
manually adjusted in service. ASAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ASA,
brake actuator or other system components.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ASA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system
For Meritor brake adjustment, refer to the brake adjustment tables
in this section. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
7
Refer to the publications in Table BJ. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
Table BJ: Publications
Model
Manual
Cam Brakes and Automatic
Slack Adjusters
Maintenance Manual 4
Automatic Slack Adjusters
Failure Analysis Manual TP-0445
Intervals
Inspect and lubricate the automatic slack adjuster according to one
of the schedules below. Use the schedule that requires the most
frequent inspection and lubrication, and whenever you reline the
brakes. Refer to Table BK for grease specifications.
앫 Vehicle manufacturer’s schedule
앫 Fleet’s schedule
앫 Every six months
앫 A minimum of four times during the life of the linings
Meritor Maintenance Manual 1 (Revised 08-06)
109
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7 Brakes
Procedures
WARNING
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
1.
Place blocks in front and behind the wheels to prevent the
vehicle from moving.
WARNING
Before you service a spring chamber, carefully follow the
manufacturer’s instructions to compress and lock the spring to
completely release the brake. Verify that no air pressure
remains in the service chamber before you proceed. Sudden
release of compressed air can cause serious personal injury
and damage to components.
2.
If the vehicle has spring brakes, manually compress and lock
the springs to release the brakes. You must check to ensure
that no air pressure remains in the service halves of the air
chambers.
Slack Adjusters Manufactured in 1993
1.
Use the correct slack adjuster template to ensure that the
clevis is installed in the correct position.
2.
Before you perform brake maintenance, check the free stroke
and the adjusted chamber stroke.
3.
If the free stroke is not correct, refer to the adjustment
procedure in this section to correct the stroke before you adjust
the chamber stroke.
4.
Inspect the boot for cuts or other damage. If the boot is cut or
damaged, remove the pawl and inspect the grease.
5.
If the grease is in good condition, replace the damaged boot
with a new boot.
6.
Use a grease gun to lubricate the slack adjuster through the
grease fitting. If necessary, install a camshaft into the slack
adjuster gear to minimize grease flow through the gear holes.
7.
Lubricate until the new grease purges from around the inboard
camshaft splines and from the pawl assembly.
110
Meritor Maintenance Manual 1 (Revised 08-06)
At Brake Reline
1.
Before you perform brake maintenance, check the free stroke
and the adjusted chamber stroke.
2.
If the free stroke is not correct, refer to the diagnostic tables in
this section to correct the stroke before you adjust the chamber
stroke.
3.
Inspect the boot for cuts or other damage. If the boot is cut or
damaged, remove the pawl and inspect the grease.
4.
If the grease is in good condition, replace the damaged boot
with a new boot.
5.
Use a grease gun to lubricate the slack adjuster through the
grease fitting. If necessary, install a camshaft into the slack
adjuster gear to minimize grease flow through the gear holes.
6.
Lubricate until new grease purges from around the inboard
camshaft splines and from the pawl assembly.
mm1.fm.book Page 111 Thursday, August 24, 2006 12:29 PM
7 Brakes
Approved Lubricants
Table BK: Automatic Slack Adjuster Grease Specifications
Components
Meritor Specification
NLGI Grade
Grease Type
Outside Temperature
Automatic Slack Adjuster
O-616-A
1
Clay Base
Down to −40° F (−40° C)
O-645
2
Synthetic Oil, Clay Base
Down to −65° F (−54° C)
O-692
1 and 2
Lithium Base
Down to −40° F (−40° C)
Any of Above
Refer to Above
Refer to Above
Refer to Above
O-637*
1-1/2
Calcium Base
O-641
—
Anti-Seize
Refer to the grease
manufacturer’s
specifications for the
temperature service limits.
Clevis Pins
* Do not mix Meritor grease specification O-637, part number 2297-U-4571, a calcium-base, rust-preventive grease, with other greases.
Table BL: Automatic Slack Adjuster Lubricant Specifications
Operating Temperature
Down to −40° F (−40° C)
Down to −65° F (−54° C)
Clay-Base Greases
Synthetic Greases
Meritor Specification O-616-A, Part Number A-1779-W-283
Meritor Specification O-645, Part Number 2297-X-4574
Shell Darina Number 1
Mobilgrease 28 (Military)
Texaco Thermatex EP-1
Mobiltemp SHC 32 (Industrial)
Texaco Hytherm EP-1
Tribolube-12 Grade 1
7
Aralub 3837
Anti-Seize Compound
Meritor lubricant specification O-637, part number 2297-U-4571,
is a corrosion-control grease. Do not mix this grease with other
greases. This compound is also available from the Southwest
Petro-Chemical Division of Witco Chemical Corporation, 1400 South
Harrison, Olathe, KS 66061, as Corrosion Control, part number
SA 8249496.
앫 Use anti-seize compound on the clevis pins of all slack adjusters.
앫 Also use anti-seize compound on the automatic slack adjuster
and cam splines if the slack adjuster gear has no grease groove
and holes around its inner diameter.
Meritor Maintenance Manual 1 (Revised 08-06)
111
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7 Brakes
Important Information
Meritor automatic slack adjusters (ASAs) should not need to be
manually adjusted in service. ASAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ASA,
brake actuator or other system components.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ASA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
For Meritor brake adjustment, refer to the brake adjustment tables
in this section. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
Automatic Slack Adjuster Troubleshooting
Diagnostic Charts
Table BM: Automatic Slack Adjuster
Conditions
Adjusted stroke
is too long
Possible Causes
Incorrect slack adjuster part number
No adjustment
Clevis installed at the incorrect angle
Adjusted stroke
is too short
Linings drag
Excessive wear between the clevis and collar, more than 0.060-inch
(1.52 mm)
Loose jam nut at clevis
Worn clevis pin bushing in slack arm, inside diameter larger than
0.53-inch (13.46 mm)
Weak or broken return spring in air chamber, spring force must be at
least 32 lb (142.4 N폷m) at first push rod movement
Spring brake does not retract fully
Worn or stripped teeth on pawl or actuator
High torque is required to rotate the worm when slack is removed from
vehicle
앫 In service slack, maximum worm torque: 45 lb-in (5.09 N폷m)
앫 New or rebuilt slack, maximum worm torque: 25 lb-in (2.83 N폷m)
Excessive looseness between camshaft splines and automatic slack
adjuster gear
Worn components, cam bushing, for example, in the foundation brake
Non-original equipment manufacturer replacement linings with
excessive swell or growth
Incorrect slack adjuster part number
Clevis installed at incorrect angle
Loose jam nut at clevis
Spring brake does not retract fully
Incorrect manual adjustment
Poor contact between linings and drum, or drum is out-of-round
Brake temperature imbalance
112
Meritor Maintenance Manual 1 (Revised 08-06)
Corrections
Check with the warehouse distributor or
original equipment manufacturer.
Use the correct template or BSAP setting to
install the clevis correctly.
Replace with a threaded clevis.
Tighten to specification.
Replace the bushing.
Replace the return spring or air chamber.
Repair or replace the spring brake.
Replace the pawl or actuator.
Rebuild or replace the slack adjuster.
Replace the camshaft, gear or automatic slack
adjuster as needed.
Replace the components.
Use Meritor-approved linings.
Check with the warehouse distributor or
original equipment manufacturer.
Use the correct template to install the clevis
correctly.
Tighten to specification.
Repair or replace the spring brake.
Adjust the brake.
Repair or replace the drums or linings.
Correct the brake balance.
mm1.fm.book Page 113 Thursday, August 24, 2006 12:29 PM
7 Brakes
Wedge Brakes
For complete maintenance and service information for Meritor
wedge brakes, refer to Maintenance Manual 4R, Wedge Brakes.
To obtain this publication, refer to the Service Notes page on the
front inside cover of this manual.
Technical Publications
How to Obtain Additional Maintenance and Service
Information
Identification
Refer to the publications in Table BN. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
Wedge brakes are identified as follows.
Table BN: Publications
앫 An example of a part number format for a 15-inch brake is
RSA 1540 1234.
Model
앫 A model number tag is typically attached to the wedge tube or
dust shield of the brake assembly.
Manual
Wedge Brakes
Maintenance Manual 4R
®
Stopmaster Wedge Brake
Model Nomenclature
Maintenance Manual MM-0153
Refer to Figure 7.28 for an explanation of brake model numbers.
Description
Meritor Stopmaster® wedge brakes for on-highway vehicles are
air-actuated and are available as single-actuated (RSA) and
dual-actuated (RDA). Both models can be specified with 12-, 14or 16-degree wedge angles. Figure 7.27.
7
Figure 7.27
4002631a
Figure 7.27
Figure 7.28
Stopmaster ® Wedge Brakes
Model Numbers and Designations
R
S
S = Single Actuation
D = Dual Actuation
Meritor —
Wedge Design
A
15
40
Drum I.D. (Inches)
Blank = No Chamber or Cylinder
A = With Air Chamber
H = With Hydraulic Chamber
1234
Speci cation Number
Specification
Number
Shoe Width (Inches)
4002716c
Figure 7.28
Meritor Maintenance Manual 1 (Revised 08-06)
113
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7 Brakes
Important Information
4.
While you rotate the drum, use an adjusting spoon to turn the
adjusting bolt until the linings drag heavily on the drum. Turn the
adjusting bolt 10-20 teeth in the opposite direction until the
lining-to-drum clearance is 0.020-0.040-inch (0.51-1.02 mm).
Operate the brakes. Use a ruler to measure movement at the
center of the shoe to determine the lining-to-drum clearance.
5.
Repeat Step 4 for the other adjuster on the brake.
6.
If the brake has a spring chamber, release the spring.
Meritor automatic brake adjusters (ABAs) should not need to be
manually adjusted in service. ABAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ABA,
brake actuator or other system components.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ABA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
For Meritor brake adjustment, refer to the brake adjustment tables
in this section. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
Brake Adjustment Procedure
WARNING
You must manually adjust the brake after you perform
maintenance or service. Do not depend on the automatic
adjusters to remove the excessive clearance created when you
back off the brake during service. The automatic adjusters are
designed to compensate for normal lining wear. Damage to
components and serious personal injury can occur.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Support the vehicle with safety stands.
Do not work under a vehicle supported only by jacks. Jacks can
slip and fall over. Serious personal injury can result.
1.
NOTE: Meritor KIT 1184 includes an adjusting spoon plus a seal
driver and a brake spring tool. The kit or the individual tools are
available from Meritor Aftermarket Parts and Services, 7975 Dixie
Highway, Florence, KY 41042. Adjusting spoons available from tool
manufacturers include Kent-Moore J-34061, Proto 2006 and
Snap-on® S-9523.
Inspection Procedure
WARNING
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
Every Two Months or 25,000-30,000 Miles
(40 000-48 000 km)
Remove the plugs from the inspection holes in the dust cover. Check
for lining wear and lining-to-drum clearance. Check for correct
operation of the service and parking brake systems as follows.
1.
Raise the vehicle so the wheel is off the ground.
WARNING
Some linings have a groove in the edge of the lining. Some
linings are scalloped at the four inner corners. Figure 7.29.
When linings are worn so that the groove or the scallops are
not visible, replace the linings.
Figure 7.29
Before you service a spring chamber, carefully follow the
manufacturer’s instructions to compress and lock the spring to
completely release the brake. Verify that no air pressure
remains in the service chamber before you proceed. Sudden
release of compressed air can cause serious personal injury
and damage to components.
GROOVED
SCALLOPED
2.
If the brake has a spring chamber, cage the spring. Rotate the
drum to verify that the brake is completely released.
3.
Remove the plugs from the adjustment and inspection slots on
the dust shield.
4002660a
Figure 7.29
114
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 115 Thursday, August 24, 2006 12:29 PM
7 Brakes
2.
On RDA brakes, the linings on both shoes should wear at
approximately the same rate. If one shoe wears much faster
than the other, correct the problem before you replace the
linings. Refer to Troubleshooting in this section.
On RSA brakes, it is normal for the leading shoe to wear faster
than the trailing shoe. The leading shoe is the first shoe past
the plunger housing in the direction of forward wheel rotation.
When the plunger housing is behind the axle, the top shoe is
the leading shoe. When the plunger housing is in front of the
axle, the bottom shoe is the leading shoe. Figure 7.30.
Figure 7.30
LEFT-HAND BRAKES
WHEEL ROTATION
RIGHT-HAND BRAKES
WHEEL ROTATION
Lubrication
Lubricate the components shown in Figure 7.31 every
100,000 miles (160 000 km), or once a year, or when any of
the following occur.
앫 The seals are replaced.
앫 The plungers are removed.
앫 The brake is relined.
앫 The grease becomes contaminated or hardened.
Use generous amounts of grease to prevent premature wear.
However, do not pack the housing with so much grease that the
components cannot move freely.
Figure 7.31
ADJUSTING BOLT
SHOE SLOT
AND THREADS
PAWL TEETH
LEADING SHOE
WHEEL ROTATION
Figure 7.30
3.
While someone operates the service and parking brake
systems, check each brake to verify that it operates correctly.
Use a ruler to measure the movement at the center of each
shoe to determine the lining-to-drum clearance. Clearance of a
shoe must not exceed 0.090-inch (2.3 mm). Total clearance of
the two shoes must not exceed 0.120-inch (3.05 mm). When
clearance exceeds these limits, the automatic adjusters are not
working correctly. Refer to the troubleshooting tables in this
section to correct the problem before you adjust the brake.
ENTIRE
ACTUATOR
ENTIRE
ADJUSTING
PLUNGER
ALL PLUNGER
HOUSING BORES
7
WEDGE HEAD
AND ROLLERS
WHEEL ROTATION
4002661a
INSIDE OF SEAL
ENTIRE PLUNGER
BELOW SEAL
GROOVE AND
AREAS OF SPIDER
ANCHOR PLUNGER
AND HARDWARE THAT
SHOE SLOT
CONTACT SHOES
INSIDE
4002659a
OF SEAL
Figure 7.31
Meritor Maintenance Manual 1 (Revised 08-06)
115
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7 Brakes
Approved Lubricants
Table BO: Wedge Brake Grease Specifications
Component
All Actuating
Components
Meritor
Specification
NLGI Grade
Grease Description
Outside Temperature
O-616-A
1
Clay Base
Down to –40° F (–40° C)
O-645
2
Synthetic Oil, Clay
Base
Down to –65° F (–54° C)
All Areas Where Shoes
Contact Spider
Anchor Plungers
Adjusting Bolts or
Retainer Hardware
Important Information
Meritor automatic brake adjusters (ABAs) should not need to be
manually adjusted in service. ABAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ABA,
brake actuator or other system components.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ABA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
For Meritor brake adjustment, refer to the brake adjustment tables
in this section. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
Wedge Brake Troubleshooting
Diagnostic Charts
Table BP: Wedge Brakes
Condition
Brakes do not apply.
Brakes do not have
enough torque during
application.
116
Possible Causes
Plugged or damaged air lines or valves
Plungers seized in housing
Correction
Repair or replace air lines or valves.
Inspect the seals, lubricant and plungers. Service as
necessary.
Push rod not connected to wedge
Inspect and correct as needed.
Brakes not adjusted correctly
Adjust the brakes correctly.
Automatic adjusters not working
Refer to Automatic slack adjusters not working.
Linings worn below minimum thickness, damaged Replace the linings.
or missing
Incorrect lining friction rating
Replace with the correct lining.
Air or spring chamber not threaded completely
Install the chamber correctly.
into plunger housing
Plungers seized in housing
Inspect the seals, lubricant and plungers. Service as
necessary.
Grease or oil on the linings
Clean or replace the linings. Check the wheel seals for leaks.
Damaged diaphragm in the air chamber
Repair or replace the air chamber.
Leaks in the air system
Repair the leaks.
Worn components
Replace the components.
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7 Brakes
Table BP: Wedge Brakes
Condition
One shoe lining wears
faster than the other,
RDA models only.
NOTE: The leading shoe
lining normally wears
faster on RSA models.
Brakes grab or vibrate
during application
Brakes drag
Possible Causes
Wedge not correctly installed in air chamber
Brake shoes installed backward
Weak or damaged shoe return springs
Wedge and roller assembly not correctly installed
in plunger ramp
Lining friction ratings do not match
One wedge roller is out of the cage
Grease or dirt on linings
Loose, worn or missing shoe retaining hardware
Lightweight or out-of-round drums
Automatic slack adjuster not operating correctly
Brakes are dragging
Unequal pressure in air chambers
Loose wheel bearings
Low air pressure at air chamber
Grease or dirt on linings
Wedge and roller assembly not correctly installed
in plunger ramp
Incorrect lining friction rating
Linings worn below minimum thickness, damaged
or missing
Shoes bind due to incorrect assembly or weak,
worn out shoes
Weak or damaged shoe return springs
Spring brake not completely released
Weak or damaged return springs
Air lines connected to incorrect ports
Leaks in the air system
Air trapped in air chamber when brakes are
released
Brake drum out-of-round
Loose wheel bearings
Push rod not connected to wedge
Plungers seized in housing
Damaged return spring or cotter pin on wedge
assembly
Grease or dirt on linings
Loose, worn or missing shoe retaining hardware
Incorrect manual adjustment
Correction
Install the wedge and air chamber correctly.
Install the shoes correctly.
Replace the return springs.
Install correctly.
Use the matched linings.
Repair or replace the wedge assembly.
Clean or replace the linings. Check the wheel seal for leaks.
Repair or replace the retaining hardware.
Replace the drums.
Refer to Automatic slack adjusters not working.
Refer to Brakes drag.
Determine the cause and repair or replace as needed.
Adjust the wheel bearings correctly.
Inspect and repair the air delivery system.
Clean or replace the linings. Check the wheel seals for leaks.
Install correctly.
Replace with the correct lining.
Replace the linings.
Install the shoes correctly or replace as needed.
Replace the return springs.
Inspect and repair the air system and spring chamber.
Replace the return springs.
Connect the air lines correctly.
Repair the leaks.
Repair or replace the release valves.
Replace the drum.
Adjust the wheel bearings correctly.
Inspect and correct as needed.
Inspect seals, lubricant and plungers. Service as necessary.
Replace the spring or cotter pin.
Clean or replace the linings. Check the wheel seals for leaks.
Repair or replace the retaining hardware.
Adjust the brake correctly.
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7 Brakes
Table BP: Wedge Brakes
Condition
Possible Causes
Correction
Automatic brake
adjusters not working
Damaged shoe retainer or detent clip on the
adjusting bolt head
Replace the adjusting bolt.
Adjusting bolt threads extend through bottom of
actuator
Install the adjusting bolt so the threads do not extend past the
bottom of the actuator.
Adjusting bolt threaded too tightly
Verify that the bolt turns freely.
Brake shoes installed backward
Install the brake shoes correctly.
Foreign material on threads of adjusting bolt or
actuator
Clean or replace the adjusting bolt and actuator. Replace the
seals as needed.
Lack of lubrication, contamination, corrosion,
damaged seals
Replace the adjuster parts and seals as needed. Lubricate at
the scheduled intervals.
Damaged teeth on pawl or actuator
Replace the pawl and plunger assembly.
Damaged pawl spring
Replace the pawl assembly.
Weak or damaged shoe return springs
Replace the return springs.
Pawl seized in its bore
Clean and replace the pawl or housing as needed.
Anchor plungers installed in the incorrect
locations
Install the plungers in the correct locations.
Broken power spring.
Repair or replace assembly as described by the manufacturer.
Power spring unable to expand completely, spring
still caged
Determine the cause and repair or replace as described by
the manufacturer.
Hold-off air not being exhausted
Determine the cause and repair or replace as described by
the manufacturer.
Air chamber assembly not threaded completely
into the plunger housing
Correctly thread the air chamber into the housing. Tighten the
collet nut to prevent loosening.
Brakes not adjusted correctly
Adjust the brakes correctly.
Grease or dirt on the linings
Clean or replace the linings. Check the wheel seals for leaks.
Spring brake does
not hold
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7 Brakes
Four-Piston Quadraulic Disc Brakes
Identification
Technical Publications
To identify the caliper, check for an assembly number on the side of
the caliper.
How to Obtain Additional Maintenance and Service
Information
Current Style
Refer to the publications in Table BQ. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
The current style caliper can be identified by the following features.
Figure 7.32.
앫 Metric caliper bolts
앫 Caliper halves are held together by bolts in blind holes in the
bridge area.
Table BQ: Publications
Model
Manual
Four-Piston Quadraulic Disc
Brake Caliper
Maintenance Manual
MM-2075
Wheel Equipment (Disc Wheel
Hubs and Brake Drum Failure
Analysis)
Maintenance Manual
MM-99100
앫 Integral piston/heat shield
앫 Phenolic piston
Figure 7.32
Description
7
Meritor’s quadraulic disc brakes have a four-piston, fixed-mount
caliper design for use on both front and rear drive axles. An
installation includes four major components — the caliper
assembly, support assembly, hub/rotor assembly and the attaching
hardware.
The inboard pistons apply the inboard pads and the outboard
pistons apply the outboard pads. Two sizes of calipers are used,
2.520-inch (64 mm) and 2.756-inch (70 mm).
Features of the caliper include the following.
CURRENT STYLE
4004060a
Figure 7.32
앫 Designed for hydraulic brake systems
앫 Hard-mounted to the anchor plate to eliminate caliper and
anchor plate replacement
앫 Designed with hardened stainless steel mounting surfaces, high
temperature piston boot compound, sealed bleeder screws and
full-coverage zinc plating
앫 Compatible with anti-lock braking systems (ABS) and existing
hydraulic systems
앫 Helps to increase lining life
앫 Can be adapted to fit most vehicles with a hydraulic system that
supplies to 1,800 psi (12 402 kPa)
Previous Style
The previous style caliper can be identified by the following features.
Figure 7.33.
앫 SAE caliper bolts
앫 Caliper halves are held together by bolts and nuts in the bridge
area.
앫 Separate piston and heat shield
앫 Metal piston
앫 Available in 33,000 lbs maximum GVWR (4 x 70 mm) and
maximum 24,000 lbs GVWR (4 x 64 mm). brake pads, two
stainless steel lining rail covers installed with button head bolts,
a pad retainer spring and bolt, bleeder screw and crossover tube
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7 Brakes
CAUTION
Figure 7.33
Use a crocus cloth to remove minor stains and corrosion from
the caliper bore. Do not use abrasives, including an every
cloth. If you cannot remove minor stains and corrosion,
replace the caliper bore to avoid damage to components.
7.
앫 If these conditions are evident: Use a crocus cloth to
remove stains or corrosion. Clean the caliper bore after
using a crocus cloth. Do not use abrasives, including an
emery cloth.
PREVIOUS STYLE
앫 If you cannot remove stains and corrosion from the
caliper bore: Replace the caliper.
4004059a
Figure 7.33
Four-Piston Quadraulic Disc Brake
Inspection
Caliper
1.
Clean the area around the brake hose. Use brake parts cleaner.
2.
Inspect the heat shields (previous style only) for wear and
damage. Replace worn or damaged shields.
3.
Inspect the caliper lining spacers for wear and damage.
Replace worn or damaged spacers.
4.
Inspect the housing for cracks or damage. Replace a cracked
or damaged housing.
6.
120
Caliper Mounting Plate
1.
Inspect caliper mounting plate area for rust, corrosion. Replace
a damaged or worn mounting plate.
2.
Use a wire brush to clean the caliper mounting area.
3.
Inspect the mounting plate for cracks or elongated bolt holes.
앫 If these conditions are evident: Replace the mounting
plate.
Bleeding the Brake System
Refer to the manufacturer’s service information for ABS bleeding
instructions.
1.
Check the master cylinder reservoir and fill, if necessary, with
DOT 3 or DOT 4 brake fluid.
2.
Bleed the brakes in the following order: right rear, left rear,
right front and left front.
3.
Inspect the outside diameter of the pistons for scoring, nicks,
corrosion, wear and damage.
Each four-piston caliper is equipped with two bleeder screws.
Loosen the inner bleeder screw, which is always on the top and
purge the air. Tighten it loosely.
4.
앫 If any of these conditions are evident: Replace the
pistons. Do not refinish or use abrasives.
Open the outer bleeder screw and purge the air and tighten the
bleeder screw to 9-12 lb-ft (1.2-16.3 N폷m). @
5.
Inspect the caliper bore for scoring, nicks, corrosion, wear and
damage.
Now again open the inner bleeder screw and purge the air and
tighten the bleeder screw to 9-12 lb-ft (12.2-16.3 N폷m). @
6.
앫 If any of these conditions are evident: Replace the
caliper.
Repeat this procedure for all other brakes in the sequence
specified in Step 2.
7.
Test the brakes prior to returning the vehicle to service. A firm
pedal should be felt during brake application.
NOTE: The outside diameter of the piston is the calipers primary
sealing surface and is manufactured to very close tolerances.
Replace a piston if the outside diameter is damaged. Do not refinish
or use abrasives, including an emery cloth, on the piston. Damage
to components can result.
5.
Inspect the caliper bore for minor stains and corrosion.
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7 Brakes
Four-Piston Quadraulic Disc Brake Troubleshooting
Diagnostic Charts
Table BR: Four-Piston Quadraulic Disc Brakes
Conditions
Possible Causes
Correction
Excessive pedal effort
Pads worn below minimum thickness
Install the new pads.
Faded, overheated condition, glazed pads,
blued or heat-checked rotors
Replace the rotor or reface the pads if sufficient lining
remains.
Grease, oil or brake fluid on linings
Install the new pads in axle sets.
Seized or frozen pistons
Disassemble the calipers and free the pistons, or
replace the caliper.
Excessive lateral runout of brake rotor
Check with a dial indicator. Install a new rotor if runout
exceeds the maximum specified.
Excessive out-of-parallelism of brake rotor
Check the parallelism, rotor thickness variation, with a
micrometer and resurface the rotor, or install a new
rotor if the parallelism exceeds the maximum allowed.
Loose or worn steering or suspension parts
Replace the parts and realign.
Excessive front bearing clearance
Readjust the bearing to specification.
Brake fluid, oil or grease on linings
Install the new pads in axle sets.
Unmatched linings, uneven lining wear,
distorted pads
Install the new pads in axle sets.
Rough rotor surfaces on one rotor
Resurface or replace the rotor in axle sets.
Seized or frozen pistons
Disassemble the caliper and repair or replace.
Loose caliper mounting bolts
Tighten to specifications.
Uneven tire pressure, tread wear or size, right
to left
Equalize to the recommended pressures. Install the
correct size tires with good tread.
Excessive rotor parallelism or runout
Resurface or replace the rotor.
Restricted hose or line
Examine the hoses and lines and replace as necessary.
Front end out of alignment
Reset the alignment.
Cylinder bore surface scored or corroded
Disassemble the calipers, clean the bore and replace
the seals and boots.
Caliper piston seal damaged or worn
Disassemble the calipers and install the new seals and
boots.
Caliper piston damaged
Replace the piston.
Pedal pulsation, brake
roughness or chatter
Vehicle pulls to one side
Leaky caliper
Meritor Maintenance Manual 1 (Revised 08-06)
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7 Brakes
Table BR: Four-Piston Quadraulic Disc Brakes
Conditions
Possible Causes
Correction
No braking effect or
excessive pedal travel
Reservoir fluid level low
Check for causes of fluid leak, repair as required and
refill the reservoir. Bleed the system as needed.
Air in the hydraulic system
Bleed the system.
Bleeder screw loose or open
Bleed the system and tighten the bleeder screw.
Caliper piston seal damaged
Disassemble the caliper and replace the piston seals.
Replace the piston if damaged.
Excessive rotor runout or bent rotor
Check the rotor with a dial indicator. Install a new rotor
if the runout exceeds the maximum specified.
Bad or excessively loose wheel bearings
Adjust or replace the bearings as needed.
Poor quality brake fluid
Drain and clean the system. Replace with the
recommended brake fluid.
Weak brake hose that expands under pressure
Replace the hoses as necessary.
Excessive lateral runout of rotor
Check the runout with a dial indicator. Install a new
rotor if the runout exceeds the maximum specified.
Lack of rotor parallelism
Check the parallelism with a micrometer. Resurface or
install a new rotor as required.
Loose wheel bearing
Readjust the bearing to the specified torque.
Rust or mud build-up on edges of rotor and on
caliper housing
Clean or replace as necessary.
Worn pad or pad installed backward
Replace the pads in axle sets only with the friction
surface against the rotor.
Incorrect caliper alignment permitting rotor to
scrape on housing
Correct the alignment.
Brake noise — groan
Pressure on the brake pedal too light
Slightly increase the pedal effort to eliminate noise.
Brake noise — rattle
Excessive clearance between the shoe and
caliper
Install the new pads.
Pad retainer spring missing or not correctly
positioned
Install a new pad retainer spring or position correctly.
Glazed pads
Resurface or replace the pads in axle sets only.
Weak pad retainer spring
Install a new pad retainer spring.
Pad wear indicator contacting rotor
Install the new pads in axle sets only.
Foreign material embedded in linings
Replace the pads in axle sets only.
Brake noise — chatter
Brake noise — scraping
Brake noise — squeal
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7 Brakes
DuraPark® Hydraulic Drum Brakes
Figure 7.36
ADJUSTER PISTON
AND MANUAL
OVERRIDE WHEEL
Technical Publications
How to Obtain Additional Maintenance and Service
Information
Refer to Maintenance Manual MM-99101, DuraPark® Type A2LS
Heavy-Duty Drum Brake Assembly. To obtain this publication, refer
to the Service Notes page on the front inside cover of this manual.
CURRENT
4002882a
Description
The DuraPark® rear hydraulic drum brake consists of a backing
plate, two brake shoe and lining assemblies, an adjuster cylinder
and park cylinder. The adjuster cylinder acts as a conventional wheel
cylinder and contains automatic adjusters which maintain a
shoe-to-drum clearance within a specified range. The park cylinder
acts as a conventional wheel cylinder and also acts to apply and
release the shoes for parking. Figure 7.34.
Figure 7.36
Figure 7.37
PARK CYLINDER WEDGE ASSEMBLY,
SLEEVE AND NON-SLEEVED
Figure 7.34
7
PREVIOUS, NON-SLEEVED
4003817a
4003817a
Figure 7.34
DuraPark® Hydraulic Brake Product Update
DuraPark® hydraulic brake changes are visible and can be seen
during various maintenance procedures. Figure 7.35, Figure 7.36,
Figure 7.37, Figure 7.38, Figure 7.39 and Figure 7.40.
CURRENT, SLEEVED
Description of Service Parts:
1) Sleeved Park Cylinders now supersede non-sleeved cylinders.
2) Sleeved Wedge Kits now supersede non-sleeved kits.
IMPORTANT INSTALLATION NOTE: Check the BRAKE CHAMBER
design level shown below, whenever you change a PARK CYLINDER
or WEDGE KIT. The original brake chamber (pre-November 1985,
shown below) is without an O-ring seal on the inside of the jam nut.
These chambers are identified by the slots in the base of the jam nut.
The new chamber design (after November 1985, shown below) has an
O-ring seal inside of the jam nut. The new chamber is without slots
in the jam nut.
If the brake chamber is the original design (with slots) and is being
used with a SLEEVED wedge assembly, the jam nut threads MUST be
sealed 360 degrees around with Permatex® FORM-A-GASKET No. 2
as shown below. This sealing will prevent the ingress of moisture into
the park cylinder.
NEW DESIGN
AFTER NOVEMBER 1985
O-RING SEAL
ORIGINAL DESIGN
PRE-NOVEMBER 1985
SLOTS
Figure 7.35
ADJUSTER PISTON
AND MANUAL
OVERRIDE WHEEL
Permatex® Apply Permatex®
is not required. to this area.
PREVIOUS
4002883a
Figure 7.37
4002881a
Figure 7.35
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7 Brakes
Adjustment Procedures
Figure 7.38
PISTON DESIGN
Measuring Shoe-to-Drum Clearance
PREVIOUS
PARK CYLINDER
HANDBRAKE
PISTON
PARK CYLINDER
EXPANDER
PISTON
ADJUSTER
CYLINDER
PISTON
NOTE: The clearance between the drum and lining may vary from
top to bottom and from left to right sides of the vehicle. This is
normal and does not indicate that service is required. In the past
design, the top shoe clearance was adjusted during reverse stops,
and the bottom shoe clearance was adjusted during forward stops.
However, with the newer design shoe return springs, both top and
bottom shoes are allowed to adjust during stops in either direction.
CURRENT
NOTE: Correct and full adjustment will only occur with the drum
rotating. Pumping the brake pedal with the vehicle stationary will not
achieve correct adjustment.
4002884a
1.
Block the front wheels to prevent the vehicle from moving
before any service work is started.
2.
Manually cage the parking brake chambers per the vehicle
manufacturer’s recommendations.
3.
Center the shoes in the drum by making two slow, hard
applications and releases of the service brakes.
4.
Remove the plugs from the lining inspection holes. Insert feeler
gauges between the lining and the drum approximately half
way across the width of the lining. The feeler gauges must be
on the lining surfaces and not in the area between the two
linings blocks.
Figure 7.38
Figure 7.39
SHOE RETURN SPRINGS
RH BRAKE
LH BRAKE
FRONT OF
VEHICLE
The normal shoe-to-drum clearance range is
0.020-0.050-inch (0.508-1.27 mm). In some circumstances,
larger clearances may be seen. In these cases, it is necessary
to add the top shoe clearance and the bottom shoe clearance.
The normal sum of the top and bottom shoe clearance is
0.040-0.100-inch (1.016-2.54 mm). Do not attempt to adjust
the clearances if they meet either of the above requirements.
Figure 7.41 and Figure 7.42.
FRONT OF
VEHICLE
CURRENT
4002885a
Figure 7.39
Figure 7.40
PISTON SEALS
Figure 7.41
FEELER GAUGE
LINING
INSPECTION
HOLE
PREVIOUS
CURRENT
4002886a
Figure 7.40
4002879a
Figure 7.41
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7 Brakes
12. Run the engine and release the park brake.
Figure 7.42
LINING
INSPECTION
HOLE
ADJUSTMENT
SLOT
ADJUSTER
SIGHT
HOLE
LINING
INSPECTION
HOLE
ADJUSTER
SIGHT
HOLE
ADJUSTMENT
SLOT
4002880a
Figure 7.42
Manual Brake Adjustment
13. Drive the vehicle slowly while checking the service and park
brakes.
NOTE: Extra caution should be taken if linings have not yet been
burnished.
14. Road test.
Brake Drums and Rotors
Technical Publications
How to Obtain Additional Maintenance and Service
Information
1.
Block the front wheels to prevent the vehicle from moving
before any service is started.
Refer to the publications in Table BS. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
2.
Release the parking brake system via a button, lever or switch
in the cab. This action pressurizes the spring chamber and
compresses the parking brake spring.
Table BS: Publications
3.
Cage the parking brake spring in accordance with your vehicle
or spring chamber manufacturer’s recommendations.
4.
Jack up the rear wheels and install safety stands.
5.
Center the shoes in the drum by making two slow, hard
applications and release of the service brakes.
6.
Manually adjust the shoes by pushing or pulling the adjusting
tool (OTC part number D9OT-2588-AR) in the direction shown.
Adjust burnished shoes to 0.020-inch (0.508 mm). Adjust new
shoes to 0.030-inch (0.762 mm).
7.
Run the engine to ensure that the park brake system is
pressurized. The cab mounted park brake button, lever or
switch should still be in the released position.
8.
Uncage the park brake spring in accordance with your vehicle
or spring chamber manufacturer’s recommended procedure.
9.
Rotate each wheel by hand to ensure that the hydraulic system
has fully released the park brakes.
10. Apply the park brake and check that the wheels cannot be
rotated by hand.
Model
Manual
Wheel Equipment (Disc Wheel
Hubs and Brake Drum Failure
Analysis)
Maintenance Manual
MM-99100
Parts Failure Analysis
Manual TP-87123
7
Brake Drum Inspection and Failure Analysis
Warnings appear before maintenance procedures to alert you to
stud and nut conditions that can affect your safety and the integrity
of the vehicle and its components.
Carefully read all of the warnings before you perform the
procedures.
The Brake Drum section provides information on brake drum wear
conditions, conditions that can affect brake drum wear, a
troubleshooting table, maintenance procedures, replacing a brake
drum and preventive maintenance tips.
This information is also available in VHS format. To obtain a copy of
the video, Brake Drum Failure Analysis, call ArvinMeritor’s Customer
Service Center at 800-535-5560 and request item number
T99105V.
11. Remove the safety stands and blocks.
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7 Brakes
Fasteners Used on a New Brake Drum Assembly for
Shipping
Table BT
Nominal Diameter
Discard Drum at
An original equipment manufacturer will use one of the methods
listed below to secure a new outboard brake drum assembly during
shipping.
16.5"
16.620"
15"
15.120"
앫 Two hexagon nuts secure the assembly. Discard these nuts at
removal. Do not use these nuts to attach disc wheels to the hub
and drum assembly.
3.
Check that the brake drum surface is concentric to the
bearings within 0.015-inch (0.381 mm) total indicator runout
(TIR). Excessive end play can result when the drum’s surface is
not concentric to the bearings, which can result in deep drum
wear on one side only.
4.
Inspect all components for corrosion before assembly,
especially the brake drum pilot and mating hub and bolt
flanges. Corroded parts can cause excessive end play, which
can result in deep drum wear on one side only.
앫 Two ball seat or two flange nuts, depending on the disc wheel
system, secure the assembly. After you remove these nuts, use
them with the additional nuts required for the system.
앫 Eight or 10 ball seat or flange nuts, depending on the disc wheel
system, secure the assembly. After you remove these nuts, use
them to attach the disc wheels to the hub and drum assembly.
Brake Drum Wear Inspection
Clean the Mounting Surfaces
Inspect brake drums when you perform maintenance and service
procedures. Refer to the brake drum wear conditions in this section
to identify the types, possible causes and corrective actions for
brake drum wear.
1.
Closely check wear patterns on the friction surface inside the
drum.
2.
The maximum allowable brake drum diameter is stamped or
cast into the outer edge of the drum. Place a brake drum
diameter gauge inside the drum. Take several measurements
within 90 degrees of each other at the open and closed edges
of the drum’s friction surface.
앫 If any of these measurements are 0.120-inch
(3.048 mm) over nominal diameter: Replace the brake
drum. Figure 7.43.
WARNING
Before you perform assembly procedures, thoroughly clean
the mounting surfaces to remove paint and contaminants,
which can loosen fasteners and cause the wheels to separate
from the vehicle. Serious personal injury and damage to
components can result.
1.
Always thoroughly clean the hub mounting surfaces where the
outboard brake drum mounts.
2.
Always thoroughly clean the brake drum’s outboard flange,
which is the mounting surface for the disc wheels.
3.
Remove dirt and contaminants from mounting surfaces before
you perform the assembly procedures. Do not apply paint to
the mounting surfaces, studs or nuts. Paint decreases a
fastener assembly’s capability to maintain clamp load.
4.
If the assembly has an inboard-mounted brake drum, clean the
hub flange areas where the disc wheels mount.
5.
If the entire assembly is off the axle spindle and you will
replace the brake drum, clean the hub mounting surfaces
where the brake drum mounts.
앫 If a brake drum is out-of-round: Replace the drum.
Figure 7.43
4001717a
Figure 7.43
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7 Brakes
Brake Drum Procedures
WARNING
Replace a worn or damaged hub assembly or disc(s), which
can cause excessive runout. A wheel(s) can separate from the
vehicle. Serious personal injury and damage to components
can result.
6.
How to Clean a Brake Drum
NOTE: Use a wet cleaning method to prevent fibers from the friction
material from becoming airborne.
Check the following areas for wear, which can be caused by
a wheel that runs loose on the hub.
Use the following procedure to clean the drums during maintenance
and service, and after machining.
앫 The pilot on a hub-piloted assembly
1.
Clean the brake drum with a cloth dampened with water or a
water-base solution.
2.
If a drum has been exposed to leaking oil or grease, perform
Step 1. Then clean the drum with a non-oil base solvent.
앫 The mounting surfaces of all hub types
앫 Outboard drum mounting surfaces
NOTE: Use a calibrated torque wrench with right- and left-hand
capabilities to tighten the ball seat mounts.
7.
Ensure that the fasteners are tightened in the correct
tightening sequence and to the correct torque specifications.
Use a torque wrench to tighten the fasteners. Figure 7.44.
Figure 7.44
+
600
TYPICAL TORQUE WRENCH,
600 LB-FT CAPACITY
4001687a
Figure 7.44
8.
If wheels have run loose on the hub, the pilot on hub-piloted
assemblies and the mounting faces of all types of hubs, or
outboard brake drum mounting faces, will show wear.
A.
B.
Replace the entire hub assembly, including the nuts.
A worn pilot or brake drum mounting surface will cause
fatigue damage to the studs, and the hub or outboard
brake drum mounting surface will not provide a flat
support for the disc wheels.
Replace a Brake Drum
WARNING
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
Before you service a spring chamber, carefully follow the
manufacturer’s instructions to compress and lock the spring to
completely release the brake. Verify that no air pressure
remains in the service chamber before you proceed. Sudden
release of compressed air can cause serious personal injury
and damage to components.
1.
Park the vehicle on a level surface. Block the wheels.
2.
Raise the vehicle. Support the vehicle with jackstands.
NOTE: Before you remove the wheel and brake drum, it may be
necessary to de-adjust the slack adjuster to provide clearance
between the brake linings and drum.
3.
Remove the wheel lug nuts. Remove the wheel assembly.
4.
Loosen the drum from the hub mounting bolts. Remove the
drum.
앫 If the drum is rusted or corroded: Treat the bolts. Apply
pressure to one side of the drum. Pull the drum from the
hub.
Replace the disc wheels.
5.
Clean the brake drum surfaces to remove dirt and
contaminants.
Meritor Maintenance Manual 1 (Revised 08-06)
127
7
mm1.fm.book Page 128 Thursday, August 24, 2006 12:29 PM
7 Brakes
6.
Measure the replacement drum in several places to ensure that
dimensions are correct.
7.
Clean the debris from the drum.
NOTE: At installation, take care that wheel bearing grease does not
contaminate the drum.
Brake Drum Wear Conditions
Most of the following wear conditions that affect a brake drum
require that you replace the drum. Refer to the brake drum
diagnostic charts in this section for possible causes of, and
corrective actions for, the following wear conditions.
What is Normal Wear?
8.
Clean the drum and hub pilots with a wire brush.
9.
Align the drum with the hub bolts. Install the drum onto the
hub. Ensure that the drum seats flat against the face of the
hub.
10. Install the locknuts onto the bolts. Tighten to the correct torque
specification. Refer to Table BU.
Brake drums wear evenly under normal operating conditions. Use
fleet history, if available, to determine the approximate wear rate of
tractor drums. Normal wear is the most common reason to remove a
brake drum from service.
What is Deep or Excessive Wear?
Table BU: Torque Specifications
It is important to inspect a brake drum for the following excessive
wear conditions, which require you to replace the drum.
Drum Locknut Sizes
Torque
Deep, Uniform Wear
5/8" diameter
95-130 lb-ft (129.2-176.8 N폷m)
3/4" diameter
200-250 lb-ft (272-340 N폷m)
Deep, uniform wear at the edge of the drum where the lining rub
path starts can result from brake drag, brake imbalance and dirt
embedded in the brake lining. Figure 7.45 and Figure 7.46.
Drum Replacements:
Blind Tapped Holes:
Figure 7.45
5/8" diameter
153-207 lb-ft (208.1-281.5 N폷m)
3/4" diameter
273-367 lb-ft (371.3-499.1 N폷m)
Preventive Maintenance Tips
앫 Use heavier brake drums to ensure braking capacity. Specify
X-10 drums to avoid various types of hot spotting.
앫 Use 20 psi or greater snubs to break in new linings, rather than
light dragging stops.
앫 Ensure that the brake drum surface is concentric to the bearings
within 0.015-inch (0.381 mm) total indicator runout (TIR).
앫 Thoroughly clean all parts prior to assembly, especially the drum
and hub pilots, and the mating hub and bolt flanges. Because
these parts fit closely together, dirt, rust or paint can cause
runout, which can shorten drum and lining life.
앫 Discard a brake drum with heat checks of one to two-inches or
more on the surface.
앫 Use component equipment manufacturer-approved replacement
linings. Vehicles are usually certified to pass FMVSS 121 original
equipment only.
128
Meritor Maintenance Manual 1 (Revised 08-06)
4001701a
Figure 7.45
mm1.fm.book Page 129 Thursday, August 24, 2006 12:29 PM
7 Brakes
Figure 7.46
Figure 7.48
4001704a
4001702a
Figure 7.48
Figure 7.46
Deep Wear on One Side of the Drum Only
Heat Checking Only on One Side of the Drum
Deep wear only on one side of the drum indicates that the drum is
not concentric with the bearing center line of the hub. No evidence
of hot spotting may be evident. Figure 7.47.
Heat checking that appears only on one side of the drum results
when a drum is not concentric to the linings. Hot spotting may or
may not be evident. However, you may also notice deep wear on the
same side of the drum. Replace the drum. Figure 7.49.
Figure 7.47
Figure 7.49
4001703a
4001705a
Figure 7.47
Figure 7.49
Uniform Heat Checking
Heat checking is fine cracks on the drum’s surface. This is a normal
condition that results from continuous heating and cooling of the
friction surface. Cracks that are one to two-inches or more are
usually deep and require that you replace the drum. Figure 7.48.
Meritor Maintenance Manual 1 (Revised 08-06)
129
7
mm1.fm.book Page 130 Thursday, August 24, 2006 12:29 PM
7 Brakes
Hot Spotting (Black Spots)
In Three Equally Distant Places. Figure 7.52.
Hot spotting is black spots on a drum’s surface that can appear in
the following ways.
Replace the brake drum.
Figure 7.52
Over the Entire Surface (Uniform). Figure 7.50.
Figure 7.50
HOT
SPOTS
REPLACE DRUM
4001708a
Figure 7.52
4001706a
Polished or Glazed Drum
Figure 7.50
A polished or glazed drum has a mirror-like finish on the friction
surface. This condition occurs with some non-asbestos linings.
Figure 7.53.
On One Side Only. Figure 7.51.
Figure 7.51
Figure 7.53
4001707a
4001709a
Figure 7.51
Figure 7.53
130
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 131 Thursday, August 24, 2006 12:29 PM
7 Brakes
Scoring (Grooving)
Broken Bolt Flange (Brake Surface Not Cracked)
Scoring (grooving) are depressions in the drum’s circumference that
are deeper than 0.10-inch and wider than 0.030-inch. Replace the
drum and linings. Figure 7.54.
NOTE: The allowable brake drum pilot clearance is 0.001-0.007
inch (0.0254-0.1778 mm).
The bolting flange is broken, but the brake’s surface may not have
cracked. Figure 7.56. This is a rare condition that usually has been
caused by an assembly interference. For example, an incorrect
drum was assembled onto a hub or spoke wheel. When the
fasteners were tightened, the clamping load cracked the flange.
Figure 7.54
Broken flanges can also occur if both brake shoes do not
simultaneously contact the drum.
Figure 7.56
4001710a
Figure 7.54
7
“Blue” Drum
The inside of the brake drum has a blue tint, and components can
be damaged or deformed. These conditions indicate that extremely
high temperatures occurred during operation. Replace the drum.
Figure 7.55.
4001712a
Figure 7.56
Figure 7.55
Broken Bolt Flange (Cracked Brake Surface)
The expanding brake shoes separated the bolt flange from the brake
drum, but the flange remained intact. Figure 7.57.
Figure 7.57
4001711a
Figure 7.55
4001713a
Figure 7.57
Meritor Maintenance Manual 1 (Revised 08-06)
131
mm1.fm.book Page 132 Thursday, August 24, 2006 12:29 PM
7 Brakes
Cracked Drum
The drum has cracked, but may not show signs of wear, heat
checking or hot spots. Figure 7.58. A drum can crack when the
parking brake is set while the brakes are extremely hot. The cooling
drum contracted on the brake shoes with enough force to crack
the drum.
Brake drum pilot interference with the hub or wheel pilot can also
cause the entire cross-section of the drum to crack, if the drum was
forced onto the pilot while interference is present.
Oil or Grease Has Penetrated the Drum’s Surface;
the Drum is Discolored
The brake system has been contaminated with oil or grease when
the following conditions are evident. It is difficult to reverse this type
of damage, because oil and grease can actually penetrate iron.
Figure 7.60.
Figure 7.60
Figure 7.58
4001716a
Figure 7.60
4001714a
Figure 7.58
Worn Brake Drum Bolt Holes
The brake drum bolt holes are worn, usually because the bolts were
not tightened to the correct torque specification. The drum pilots
may also be worn, and runout in the brake drum may have
occurred. The mating hub or wheel pilots may be extensively
damaged. Replace both the hub and drum. Figure 7.59.
1.
Oil and grease spots have penetrated the drum’s surface.
2.
The brake drum is discolored.
3.
Oil and grease spots are evident on the components, which
resulted from the wheel or hub oil seals that leaked.
4.
Replace the drum.
Conditions That Can Affect Brake Drum Wear
Brake Drag
Figure 7.59
앫 Worn camshaft bushings
앫 Relay valves do not work correctly
앫 Automatic slack adjuster does not work correctly
앫 Manual slack adjuster set too tight
앫 Bent air chamber push rods
앫 Weak or broken air chamber or shoe return springs
앫 Swelling and growth of new linings
앫 Total vehicle air brake system imbalance
앫 Clogged air exhaust ports
4001715a
Figure 7.59
132
Meritor Maintenance Manual 1 (Revised 08-06)
앫 Restricted or pinched air hoses or tubing
앫 Imbalanced “apply” and “release” threshold pressures
mm1.fm.book Page 133 Thursday, August 24, 2006 12:29 PM
7 Brakes
Too Much Drum-to-Pilot End Play (Gap)
Heavy Braking
앫 Mating hub or wheel pilot machined under size
앫 Inadequate braking system for operation
앫 Hub or wheel pilots not concentric to bearing bores
앫 Linings not component equipment manufacturer-approved
앫 Brake drum assembled on contaminated or corroded hub pilots
앫 Poor driver technique
앫 Drum incorrectly assembled onto pilot
앫 High-temperature applications, such as city and construction
driving
앫 Drum not concentric to lining
Drum Seats Incorrectly on the Hub or Pilot Wheel
앫 Corroded mounting surfaces
앫 Corroded aluminum hub and drum assembly
앫 Iron or aluminum hub pilot not cleaned correctly prior to
installation
Both Shoes Do Not Simultaneously Contact the
Drum
앫 Brake drum not concentric with the bearing center line of
the hub
앫 Brake imbalance
앫 Bent spiders; or bent shoes that do not uniformly contact the
brake surface
Brake Imbalance
앫 Pneumatic imbalance between axles
앫 Relay valves do not work correctly
앫 Linings are not component equipment manufacturer-approved
앫 Incorrect brake power (AL Factor)
앫 Imbalanced “apply” and “release” threshold pressures
7
Brake Drum Diagnostics
Table BV: Troubleshooting Brake Drum Wear
Condition
Possible Cause
Corrective Action
Deep, uniform drum wear
Brake drag
Replace the drum.
Brake imbalance
Install dust shields. If dust shields
are installed, remove the shields and
try operating the vehicle without
them.
Dirt and contaminants imbedded in the brake lining
Incorrect driving technique
Engine retarder not installed
Braking with hand valve
Not downshifting on steep grades
Exceeding vehicle’s brake capacity
Deep drum wear on one side
only
Brake drum dropped, bent or machined out-of-round
Replace the drum.
Worn brake drum bolt holes
Incorrect torque applied to bolt, which also causes hub and
drum pilots to wear. Runout also occurs.
Replace the drum.
Uniform heat checking, fine
cracks
Heavy braking
Replace the drum.
Heat checking on one side only
Drum dropped, bent or machined out-of-round
Replace the drum.
Drum-to-pilot fit has too much end play, gap
Fine cracks on drum’s surface from normal operation
Drum-to-pilot fit has too much play, gap
Meritor Maintenance Manual 1 (Revised 08-06)
133
mm1.fm.book Page 134 Thursday, August 24, 2006 12:29 PM
7 Brakes
Table BV: Troubleshooting Brake Drum Wear
Condition
Possible Cause
Corrective Action
Uniform hot spotting, black
spots, on the drum’s surface
Brake lining and drum mating surfaces burnished too slowly
Replace the drum.
Brake drag
Extremely hard linings
Lining swell from poor-quality linings
Hot spotting, black spots, on one
side only
Brake drum not concentric to the lining
Replace the drum.
Drum dropped, bent or machined out-of-round
Drum-to-pilot fit has too much play, gap
Hot spotting, black spots, on
three equally-distant places
Brake lining and drum mating surfaces burnished too slowly
Replace the drum.
Braking with light, dragging stops
Linings not component equipment manufacturer-approved
Uneven brake surface contour caused by incorrect
manufacturing process
Brake drag
Polished or glazed drums,
mirror-like shine
Low-pressure braking
Scoring, Grooving
Dirt or contaminants in the brake system
Deep grooves in the drum’s
surface that exceed the drum’s
maximum diameter. Drum can
appear to be in good condition.
Linings worn to the rivets or not component equipment
manufacturer-approved
“Blue” drum
Braking generates extremely high temperatures caused by
axle wheel-end imbalance
Inside of the brake drum has
“blue” tint from excessive heat.
Components can be deformed or
damaged.
Replace the drum.
Linings not aggressive enough or not component equipment
manufacturer-approved
Check for dirt embedded in the
lining.
Install dust shields. If dust shields
are installed, remove the shields and
try operating the vehicle without
them.
Replace the drum.
Poor driver techniques
Linings not component equipment manufacturer-approved
Brake system incorrectly spec’d for the application
Brake drag
Cracked drum
Drum has cracked, but may not
show signs of wear, heat
checking or hot spotting.
The parking brake is set while the brakes are extremely hot.
The cooling drum contracts on the brake shoes with enough
force to crack the drum.
Brake drum pilot interference with the hub or wheel pilot
Drum cracked prior to assembly
134
Meritor Maintenance Manual 1 (Revised 08-06)
Replace the drum.
mm1.fm.book Page 135 Thursday, August 24, 2006 12:29 PM
7 Brakes
Table BV: Troubleshooting Brake Drum Wear
Condition
Possible Cause
Corrective Action
Broken bolt flange, brake
surface not cracked
The brake drum pilot interferes with the hub or wheel pilot.
Drum cracks at installation.
Replace the drum.
High temperatures cause expanding brake shoes to
separate the bolt flange from the drum
Incorrect drum assembly on a spoke wheel
Brake drum not seated correctly on the hub or pilot wheel
Both brake shoes do not contact the drum simultaneously
Broken bolt flange, cracked
brake surface
Excessive wear, heat checking or hot spotting
Oil or grease has penetrated the
drum’s surface; the drum is
discolored
Wheel or hub oil seals leak
Replace the drum.
Any combination of the above
Attempt to remove oil and grease
spots from the drum.
If you cannot completely remove the
oil and grease spots, you must
replace the drum.
Oil and grease spots have
penetrated the drum’s surface
and are evident on components.
7
Discolored drum
Rotors
Measuring the Thickness of the Rotor or Disc
Rotors that are damaged or worn beyond the specified thickness
can reduce the life of the brake linings.
Measure the thickness of the rotor or disc when you reline the
brakes. A solid rotor or disc must be at least 0.779-inch (19.8 mm)
thick. Rotors or discs with vents must be at least 1.626-inches
(41.3 mm) thick. If the thickness of the rotor or disc is less than
specification, always replace the rotor or disc. Figure 7.61.
Inspect the rotors whenever you inspect the brakes.
Measure the thickness of the rotor or disc whenever you reline the
brakes.
Figure 7.61
Rotor Wear Inspection
0.779" (19.8 MM)
MINIMUM THICKNESS
CAUTION
SOLID DISC
You must always replace a damaged rotor or disc.
When you inspect the brakes, inspect both sides and the outer
diameter of the rotor or disc for the following conditions. Refer to
Brake Drum Wear Conditions in this section for photographs that
illustrate these conditions.
1.626" (41.3 MM)
MINIMUM THICKNESS
앫 Cracks
VENTED DISC
4001603a
앫 Heat checking
앫 Grooves or scores
Figure 7.61
앫 Blue marks or bands
Meritor Maintenance Manual 1 (Revised 08-06)
135
mm1.fm.book Page 136 Thursday, August 24, 2006 12:29 PM
8 Rear Drive Axles
Hazard Alert Messages
Description
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
Meritor produces medium- and heavy-duty rear drive axles to suit a
wide range of vocations. Models are available in a variety of ratios to
meet many performance requirements.
8 Rear Drive Axles
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
Single rear axles are front mounted into the axle housing and have a
hypoid bevel drive pinion and ring gear set with straight bevel gears
in the differential assembly.
A tridem is a series of three driving axles configured as follows.
앫 1 axle is the forward axle of a normal tandem axle set.
앫 2 and 3 axles are a normal tandem set.
Identification
Technical Publications
How to Obtain Additional Maintenance and
Service Information
Refer to the publications in Table BW. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
To identify the axle, carrier and housing models, refer to the three
identification tags located on the main axle housing. Figure 8.1.
Specify the information stamped on these tags when you obtain
replacement parts.
Figure 8.1
Table BW: Publications
Model
*Single-Reduction Differential
Carriers
*Single-Reduction Rear
Differential Carriers
*Tandem Axle Forward Rear
Drive Units
*Tandem Axle Forward Rear
Drive Units
*Tandem Axle Forward
Carriers and Single Axle
Carriers
*Single-Reduction Forward
Differential Carriers on
Tandem and Tridem Axles
*Tandem Axle Forward Rear
Drive Units
*Tandem Axle Forward Rear
Drive Units
Double-Reduction Differential
Carriers
Drive Axle Housings
Two-Speed Differentials
Rear Drive Axles
Manual
Maintenance Manual 5
CARRIER PART NO.
CUSTOMER NO.
SERIAL NO.
RATIO
Maintenance Manual 5A
.
l No .
de r No
Mo me
sto .
Cu
l No
ria
Se
tio
Ra
Maintenance Manual 5B
nt
Pla
te
Da
Maintenance Manual 5C
Maintenance Manual 5E
Model No.
Customer No.
Serial No.
Ratio
AXLE
IDENTIFICATION TAG
Maintenance Manual 5L
Maintenance Manual 5P
Maintenance Manual 6B
Maintenance Manual 6C
Maintenance Manual 8
Maintenance Manual MM-0144
Failure Analysis Manual TP-0445
Meritor Maintenance Manual 1 (Revised 08-06)
Plant
Date
CARRIER PART NO.
CUSTOMER NO.
SERIAL NO.
RATIO
CARRIER
IDENTIFICATION TAG
4000625a
Figure 8.1
* For a complete description of product coverage for each manual, visit the
DriveTrain Plus™ by ArvinMeritor Tech Library at arvinmeritor.com.
136
AXLE HOUSING
IDENTIFICATION TAG
mm1.fm.book Page 137 Thursday, August 24, 2006 12:29 PM
8 Rear Drive Axles
Meritor, Rockwell Tags
Meritor and Rockwell tags contain similar information.
The carrier identification tag includes:
앫 Carrier part number
앫 Carrier serial number
앫 Carrier gear ratio
The axle housing identification tag includes:
앫 Housing part number
앫 Housing serial number
The axle (carrier and housing assembly) identification tag
includes:
앫 Axle assembly model number
앫 Axle assembly serial number
앫 Axle assembly customer number
앫 Carrier gear ratio
The only difference between brands is the model number.
An example of a Meritor axle assembly model number is:
MD20145DANN123.
8
An example of a Rockwell axle assembly model number is:
RD20145NFNN123.
Meritor Maintenance Manual 1 (Revised 08-06)
137
mm1.fm.book Page 138 Thursday, August 24, 2006 12:29 PM
8 Rear Drive Axles
Model Nomenclature
Axle Model Numbers and Designations
Refer to Figure 8.2 and Figure 8.3 for an explanation of rear axle model numbers.
Figure 8.2
GAWR
HOUSING WALL
xx = GAWR (000) Pounds or Tonnes
(dependent on mfg. location)
0
1
2
3
4
5
6
7
8
9
RELATIVE
GEARING SIZE
OR SERIES
AXLE MODEL TYPE
S=
X=
D=
N=
P=
R=
T=
Z=
C=
H=
Single Rear (Solo)
Front Drive Steer
Fwd Rear w/IAD
Fwd Rear less IAD
Fwd Rear w/Pump
Rear Rear
Tandem Drive
Tridem Drive
Coach
High Entry
0
1
2
3
4
5
6
7
8
=
=
=
=
=
=
=
=
=
No Gearing
292/347
337/387
TBD
381/432
415/432
432/457
457
460/498
=
=
=
=
=
=
=
=
=
=
Cast
TBD
0.31 in.
0.37/0.39 in.
0.43 in.
0.50/0.51 in.
0.56 in.
TBD
0.63 in.
TBD
(8 mm)
(9.5/10.0 mm)
(11 mm)
(12.7/13.0 mm)
(14.3 mm)
(16 mm)
CARRIER VARIATION
A=
D=
M=
N=
R=
Aluminum
Ductile
Ductile Rear (Amboid)
No Carrier
Ductile Front Drive Axle
Carrier (Right Hand)
T = Ductile Telma
Ratio 1
Ratio 2
M X - xx - 1 4 x x N - x - N 123 - xxxx - xxxx
AXLE TYPE
M = Meritor
0
1
2
3
4
5
6
7
9
=
=
=
=
=
=
=
=
=
No Carrier
Single Speed
Two Speed
Helical Dbl Red
Salisbury
Planetary Dbl Red
Hub Reduction
Portal
Single Speed with Torque
Output Limited Engine
SPEC NUMBER
N=
S=
E=
A=
Includes: TRACK, PARKING
BRAKE, OTHER
North America
South America
Europe
Australia/Asia/Africa
WHEEL END/BRAKE ATTACHMENT/DIFFERENTIAL
BRAKE TYPE
A=
B=
C=
D=
E=
F=
G=
H=
J =
K=
L =
M=
N=
P=
Q=
R=
S=
B =
C =
D =
E =
F =
G=
H =
K =
L =
N =
P =
Q=
R =
S =
T =
W=
Conventional Spindle/Conventional Brake/Standard Differential
Conventional Spindle/Conventional Brake/DCDL
Conventional Spindle/Conventional Brake/NoSPIN®
Conventional Spindle/Conventional Brake/Other Differential
Unitized Spindle/Conventional Brake/Standard Differential
Unitized Spindle/Conventional Brake/DCDL
Unitized Spindle/Conventional Brake/NoSPIN®
Unitized Spindle/Conventional Brake/Other Differential
Conventional Spindle/Integral Brake/Standard Differential
Conventional Spindle/Integral Brake/DCDL
Conventional Spindle/Integral Brake/NoSPIN®
Conventional Spindle/Integral Brake/Other Differential
Unitized Spindle/Integral Brake/Standard Differential
Unitized Spindle/Integral Brake/DCDL
Unitized Spindle/Integral Brake/NoSPIN®
Unitized Spindle/Integral Brake/Other Differential
Bolt on Conventional Spindle/Conventional Brake/No Differential
Figure 8.2
138
MFG LOCATION
Meritor Maintenance Manual 1 (Revised 08-06)
“B” Frame Brake
Air Disc Brake
Wedge Brake (Dual Air Chambers)
Wedge Brake (Dual Hydraulic Cylinders)
Wedge Brake (Single Hydraulic Cylinder)
DuraPark Hydraulic Drum
Quadraulic Disc
Disc Plus Air Disc
Q Plus™ Cam Brake
None
“P” Series Cam Brake
“Q” Series Cam Brake
Cast Plus™ Brake
Wedge Brake (Single Air Chamber)
“T” Series Cam Brake
“W” Series Cam Brake
4002693a
mm1.fm.book Page 139 Thursday, August 24, 2006 12:29 PM
8 Rear Drive Axles
Figure 8.3
BRAKE TYPE
GEARING TYPE
1
2
3
4
5
6
=
=
=
=
=
=
Single Speed
Two Speed
Helical Double-Reduction
Salisbury Single Speed
Planetary Double-Reduction
Hub Reduction
MAIN DIFFERENTIAL NEST TYPE
B=
C=
F=
H=
N=
NOMINAL AXLE LOAD
RATING (GAWR)
MANUFACTURING
LOCATION
In thousands of pounds. Individual
forward and rear axles of a tandem
set (D, N, P, R) are rated as single
axles. A tandem set (T) is rated as
the combination of the two axles
and a tridem set (Z) as the
combination of the three axles.
Meritor
Special Differential
Driver Controlled Differential Lock
Standard Differential
High Traction® Differential
No-SPIN®
A=
B=
C=
D=
E=
M=
N=
Australia
Brazil (Braseixos)
India
Mexico (Dirona)
Europe (C.V.C.)
Europe (Maudslay)
U.S.A.
B =
C =
D =
E =
F =
G=
H =
K =
L =
N =
P =
Q=
R =
S =
T =
W=
Reaction Beam Disc Brake (B-Frame)
Air Disc Brake
Wedge Brake (Dual Air Chambers)
Wedge Brake (Dual Hydraulic Cylinders)
Wedge Brake (Single Hydraulic Cylinder)
DuraPark Hydraulic Drum
Quadraulic Disc
Disc Plus Air Disc
Q Plus™ Cam Brake
None
“P” Series Cam Brake
“Q” Series Cam Brake
Cast Plus™ Brake
Wedge Brake (Single Air Chamber)
“T” Series Cam Brake
“W” Series Cam Brake
AXLE SPECIFICATION NUMBER
Identifies specific customer axle
configurations (variations from the
original axle design). For information
about the variation, refer to the Bill of
Materials for that specific axle model.
RR 20 1 4 5 N C Q F* 123
8
HUB TYPE
A = Aluminum
C = Cast Spoke Wheel
F = Ferrous
N = None
*NOTE: This position will be used to designate hub only
until more than three digits are required to designate
axle specification.
AXLE TYPE
C = Single Rear Drive Axle, Coach
D = Forward-Rear Axle of a Drive Tandem
with Inter-Axle Differential
F = Front Drive Axle
N = Forward-Rear Axle of a Drive Tandem or
Tridem without Inter-Axle Differential
P = Forward-Rear Axle of a Drive Tandem
with Inter-Axle Differential and Pump
R = Rear-Rear Axle of a Drive Tandem
S = Single Rear Drive Axle
T = Tandem Drive Axle Set
Z = Tridem Drive Axle Set
AXLE DESIGN VARIATION
CARRIER TYPE
Carrier size. Larger numbers
indicate a higher GCW rated
carrier; i.e., larger ring gear, etc.
(Also refer to Tridem Axle Note 2
below)
NOTE 2, FOR TRIDEM AXLES ONLY:
For a Tridem Drive Axle Set (RZ), the number
in the sixth position designates the carrier in
the rst axle . The number in the seventh
position designates the carriers in the second
and third axles.
Indicates axle design level or variation, (e.g., RS 23 161
has a thicker wall housing than the RS 23 160). For
information, refer to the Bill of Materials for that speci c axle
model. (Also refer to Tridem Axle Note 2 below.)
NOTE 1:
If a complete axle designation is not required, use the rst se ven
positions of the model designation to identify the basic axle model.
RS 17 145 = Single Rear Drive, 17,000 lbs., Single Speed, 15"
Ring Gear, 145 Carrier Model.
RT 52 380 = Tandem Drive Axle Set, 52,000 lbs., Helical
Double-Reduction, 19.62" Ring Gear, 380 Carrier
Model.
RZ 60 164 = Tridem Drive Axle Set, 60,000 lbs., Single Speed,
Includes a 160 Series Forward Rear or First Axle
and a 145 Series Tandem Axle Set as the Second
and Third Axles.
4002694a
Figure 8.3
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8 Rear Drive Axles
Inspection
Carrier
Check magnets and magnetic drain plugs, breathers, seals and
temperature indicators during regularly-scheduled oil checks and
changes.
CAUTION
Fill axles with specified lubricants only. Filling an axle with
non-approved lubricants will void Meritor’s warranty. Damage
to axle components also can result.
Breather
CAUTION
Cover the breather when steam cleaning the housing to
prevent water from entering the housing and contaminating
the oil. Damage to components can result.
Baffle-type breathers release pressure and vacuum condensation to
minimize premature oil and component failure.
Temperature Indicators
CAUTION
To avoid axle component damage, fill axles with approved lubricants
only. Using non-approved lubricants also will void Meritor’s warranty.
NOTE: For information on lubricant suppliers, refer to technical
bulletin 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.
Magnets and Magnetic Drain Plugs
Axles can operate above 190° F (88° C) without damage.
However, if the oil temperature reaches 250° F (121° C), stop
the vehicle immediately and check for the cause of
overheating. Damage to components can result.
Some axles may have a tapped hole in the housing to install a
temperature indicator. A temperature indicator monitors oil
temperature and helps to maximize component life, which can be
shortened by high oil temperatures that result from severe operating
conditions, or unequally inflated and mismatched tires.
NOTE: Inspect the magnetic drain plug each time the oil is
changed. Use the correct part. Pipe plugs will leak if used as a
drain plug.
Oil Seals
Although axles are normally equipped with magnetic plugs having
a minimum pick-up capacity of 1.5 lbs (0.7 kg) of low carbon
steel, Advanced Lube axles have stronger magnetic cleansing
features.
Always use the correct tools and procedures when replacing
seals to prevent incorrect installation, leaking seals and
damage to components.
These axles are equipped with strong 5-lb (2.2 kg) pull magnets,
and high-grade magnetic fill and drain plugs that collect damaging
particles at the bottom of the axle housing.
Seals keep lubricant in and dirt out of a component. When they are
worn or damaged, seals leak and produce damaging low lubricant
levels.
Tandem axles have four magnets in each housing and high-grade
magnetic fill and drain plugs. Single axles have six magnets in each
housing and high-grade magnetic drain and fill plugs.
Durable triple-lip pinion seals protect the quality and levels of the
lubricant and provide superior performance. Advanced Lube axles
have triple-lip seals designed to work with current and future
lubricants.
Check the drain plug for metal particles every 100,000 miles
(160 000 kilometers). A magnetic drain plug can be used if the plug
has a minimum pick-up capacity of 1.5 lbs (0.7 kg) of low carbon
steel after cleaning.
140
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CAUTION
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8 Rear Drive Axles
How to Recognize a Leaking Seal
Figure 8.4
If you notice moisture, wetness or oil drips on or around an axle oil
seal, it’s important to recognize if the seal is leaking, or if it only
appears to be leaking.
Inspect the oil seal and surrounding area for wetness. If the seal and
area appear very wet or visibly drip oil, or if you notice oil dripping
from the bottom of the output seal retainer, replace the seal.
Inspect the yoke for wetness. Check for a leak path leading to the
rear lip of the seal. If you notice wetness around the yoke hub or a
leak path leading to the rear lip of the seal, replace the seal.
How to Recognize a Seal That Appears to be Leaking
Seals come prelubricated with grease that melts at low
temperatures under normal operating conditions. Melted grease can
moisten or wet the area between the lip of the oil seal. When this
happens, you won’t find a leak path leading to the seal. If you notice
a moist seal and don’t find a leak path, do not replace the seal.
A seal can also become moist from lubricants applied to the yoke or
retainer bolts during assembly. When this happens, you won’t find a
leak path leading to the seal. If you notice a moist seal and don’t find
a leak path, do not replace the seal.
Seal Test Procedure
1.
Thoroughly clean and dry the area around the entire seal
retainer casting, especially at the top.
2.
Drive the vehicle for 15-20 minutes at highway speeds.
3.
Check for wetness or moisture on or around the seal. Also
check for oil dripping from the seal. If you notice either of these
conditions, replace the seal.
4005123a
Figure 8.4
Figure 8.5
8
Example 1: The Seal is not Leaking
Cause of Failure
None
What To Look For
The area around the seal is dry. There’s no evidence of displaced
packing grease or a leak path. Figure 8.4 and Figure 8.5.
Prevention
Follow Meritor’s recommended maintenance practices and service
procedures.
4005124a
Figure 8.5
Meritor Maintenance Manual 1 (Revised 08-06)
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8 Rear Drive Axles
Example 2: The Seal Appears to be Leaking
Example 3: The Seal is Leaking
Cause of Failure
Cause of Failure
A failure is possible. Inspect the seal. If a failure has occurred,
determine its cause.
Most likely, dirt or contaminants have entered the seal, or the seal’s
service life is expended.
What To Look For
What To Look For
Seals are prelubricated with packing grease that melts at low
temperatures during normal operating conditions. In Figure 8.6,
you’ll see the melted grease at the forward output through-shaft
area.
Inspect the oil seal and surrounding area for wetness. If the seal and
area appear very wet or visibly drip oil, or if you notice oil dripping
from the bottom of the output seal retainer, the seal requires
replacement.
Check the lubricant level. If it’s low, replace the seal. If not, monitor
the seal for leaks.
Prevention
Inspect the yoke for wetness. Check for a leak path leading to the
rear lip of the seal. If you notice wetness around the yoke hub or a
leak path leading to the rear lip of the seal, replace the seal.
Figure 8.7, Figure 8.8 and Figure 8.9.
Follow Meritor’s recommended maintenance practices and service
procedures.
Prevention
Follow Meritor’s recommended maintenance practices and service
procedures.
Figure 8.6
Figure 8.7
4005120a
4005121a
Figure 8.6
Figure 8.7
142
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8 Rear Drive Axles
Lubrication
Figure 8.8
Advanced Lube Axles
Advanced Lube axles require different drain intervals than other
axles. Refer to Table BX.
The vehicle manufacturer may attach a tag at the axle fill hole or on
the inside of the door to identify an Advanced Lube axle. The tag
specifies that the axle is filled with semi-synthetic or full-synthetic
gear oil.
R-170 Axles Equipped with Traction
Equalizer®
R-170 axles with traction equalizer normally operate with either
standard petroleum, semi-synthetic gear oils or full-synthetic
gear oils.
Limited Slip Friction Modifiers
4005122a
Figure 8.8
Occasionally the Traction Equalizer® will slip or stick. When this
happens, you will hear intervals of shrill noises when the vehicle
operates at low speed or when the vehicle makes sharp turns. You
can correct this condition by adding limited slip friction modifiers.
NOTE: Limited slip friction modifiers usually deteriorate more
quickly than Extreme Pressure (EP) additives. Shorten the lubricant
change schedule when using a friction modifier.
Figure 8.9
앫 At the initial lubricant change interval for an R-170 axle
equipped with a Traction Equalizer®: Replace the
factory-installed lubricant with an approved lubricant and one of
the additives specified in Table CD.
앫 After the initial change interval: Change the lubricant and the
additive at or before 50,000 miles (80 000 km).
4005125a
Figure 8.9
Meritor Maintenance Manual 1 (Revised 08-06)
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8
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8 Rear Drive Axles
Fill Plug Locations
1.
Figure 8.13
If the fill plug is only in the axle housing bowl, use that fill plug.
Do not use the temperature sending unit hole. Figure 8.10.
FRONT-MOUNTED SINGLE-REDUCTION AXLES
DRIVE PINION ANGLE
MORE THAN 7° USE AXLE
HOUSING FILL PLUG
HOUSING
FILL PLUG
Figure 8.10
Oil level must be
even with bottom
of fill plug hole.
DRAIN PLUG
1003327a
Figure 8.13
FILL PLUG
TEMPERATURE INDICATOR
PLUG — DO NOT REMOVE
Figure 8.14
1003324a
FRONT-MOUNTED SINGLE-REDUCTION TANDEM AXLES
FILL PLUG
Figure 8.10
2.
If the drive pin angle is 7 degrees or less, use the fill plug in the
differential carrier. Figure 8.11 and Figure 8.16.
3.
If the drive pin angle is more than 7 degrees, use the fill plug in
the axle housing bowl. Figure 8.13 through Figure 8.17.
HYPOID GEARING
WITH INTER-AXLE
DIFFERENTIAL
DRAIN PLUG
FILL PLUG (NOT SHOWN)
DRAIN PLUG
Figure 8.11
FILL PLUG LOCATION IN BACK OF
AXLE HOUSING BOWL
FILL PLUG
1003328a
Figure 8.14
Figure 8.15
FRONT-MOUNTED SINGLE-REDUCTION
TANDEM AXLES
FILL PLUG (NOT SHOWN)
TEMPERATURE INDICATOR
PLUG — DO NOT REMOVE
HYPOID GEARING
WITH INTER-AXLE
DIFFERENTIAL AND PUMP
FORCED LUBRICATION
1003325a
Figure 8.11
Figure 8.12
DRAIN PLUG
FRONT-MOUNTED SINGLE-REDUCTION AXLES
CARRIER
FILL PLUG
Figure 8.15
DRIVE PINION ANGLE
7° OR LESS USE
CARRIER FILL PLUG
DRAIN PLUG
Figure 8.12
144
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1003326a
1003329a
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8 Rear Drive Axles
Drain and Replace the Oil
Figure 8.16
FRONT-MOUNTED DOUBLE-REDUCTION
AND TWO-SPEED AXLES
NOTE: Drain the oil when it is warm. Remove and replace the oil
filters each time the oil is drained.
FILL HOLE
IN CARRIER
1.
Refer to Fill Plug Locations in this section.
2.
Park the vehicle on a level surface. Place blocks under the
front wheels to prevent the vehicle from moving. Place a large
container under the axle.
3.
Install the drain plug. Tighten the plug to 35-50 lb-ft
(48-67 N폷m). @
FILL PLUG
DRAIN PLUG
1003330a
Figure 8.16
앫 If an oil pump is used: Remove and replace the oil filters.
Figure 8.17
앫 For Advanced Lube axles: Replace the oil filter every
100,000 miles (160 000 km).
FRONT-MOUNTED DOUBLE-REDUCTION
AND TWO-SPEED AXLES
4.
Clean the area around the fill plug. Remove the fill plug from
the differential carrier of the axle housing bowl, depending on
the axle. Do not remove the temperature indicator plug.
5.
Add the specified oil until the oil is even with the bottom of the
fill plug hole. Wait to allow the oil to flow through the axle.
FILL HOLE IN
AXLE HOUSING
FILL PLUG
앫 If the inter-axle differential has a top fill plug hole: Add
an additional two pints (0.946 liters) of the same oil into the
inter-axle differential housing.
DRAIN PLUG
1003331a
Figure 8.17
6.
Check the oil level again. If necessary, continue to add oil until
it is even with the bottom of the fill plug hole.
7.
Install the fill plug. Tighten the plug to 35-50 lb-ft (48-67 N폷m).
Check and Adjust the Oil Level
Check the oil level when the axle is at room temperature. When hot,
the oil temperature may be 190° F (88° C) or more and can cause
burns. A correct level is not obtained when the axle is warm or hot.
Serious personal injury and damage to components can result.
1.
2.
Park the vehicle on a level surface. Place blocks under the
front wheels to prevent the vehicle from moving. The axle must
be cold or near room temperature.
Clean the area around the fill plug. Remove the fill plug from
the differential carrier or the axle housing bowl, depending on
the axle. Do not remove the temperature indicator plug.
Figure 8.11 through Figure 8.17.
3.
Check the oil level. The level must be even with the bottom of
the fill plug hole. Figure 8.10.
4.
Install the fill plug. Tighten the plug to 35-50 lb-ft (48-67 N폷m).
@
Inter-Axle Assemblies with Separate
Housings
SLHD, SQHD, STDD and SFDD forward-rear tandem axle carrier
models include separate housings for inter-axle differential
assemblies.
The baffles and dams used in these housings hold a reservoir of oil
that can also trap wear particles and debris. Always purge the oil
from these reservoirs when changing the axle oil.
These carriers have separate drain and fill holes in either the
inter-axle differential cover or housing.
@
Meritor Maintenance Manual 1 (Revised 08-06)
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8 Rear Drive Axles
Lubrication Intervals and Specifications
Lubrication Analysis Recommendations
Meritor recommends using a lubricant analysis program. Perform lubricant analysis at regularly-scheduled preventive maintenance intervals.
Refer to Section 1 for drive axle differential oil analysis guidelines.
Table BX: Oil Change Intervals for All Rear Drive Axles
Construction, Transit Bus,
Refuse, Yard Tractor, Logging,
Heavy Haul, Mining, Oil Field,
Rescue
Vocation or Vehicle
Operation
Linehaul
Intercity Coach
City Delivery, School
Bus, Fire Truck,
Motorhome
Initial Oil Change
Not required
Not required
Not required
Not required
Check Oil Level
Every 25,000 miles
(40 000 km), or the
fleet maintenance
interval, whichever
comes first
Every 25,000 miles
(40 000 km), or the fleet
maintenance interval,
whichever comes first
Every 10,000 miles
(16 000 km), once a
month, or the fleet
maintenance interval,
whichever comes first
Every 5,000 miles (8000 km),
once a month, or the fleet
maintenance interval, whichever
comes first1
Every 100,000 miles
(160 000 km) or
annually, whichever
comes first
Every 100,000 miles
(160 000 km) or
annually, whichever
comes first
Every 50,000 miles
(80 000 km) or annually,
whichever comes first
Every 25,000 miles (40 000 km)
or annually, whichever comes
first
Every 500,000 miles
(800 000 km), or
every 4 years,
whichever comes
first
Every 250,000 miles
(400 000 km), or every
4 years, whichever
comes first
Every 250,000 miles
(400 000 km), or every
3 years, whichever comes
first
Every 100,000 miles
(160 000 km), or every 2 years,
whichever comes first3
Every 100,000 miles
(160 000 km)
Every 100,000 miles
(160 000 km)
Every 100,000 miles
(160 000 km)
Every 100,000 miles
(160 000 km)
Add the correct type
and amount of oil as
required.
Petroleum-Based Oil
Change on axles
with or without a
pump and filter
system.
Synthetic Oil
Change on axles
with or without a
pump and filter
system.2
Filter Change
Change on axles
with a pump and
filter system.
1
2
3
For continuous heavy-duty operation, check the oil level every 1,000 miles (1600 km).
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.
The change interval for transit bus can be increased to 150,000 miles (241 401 km) or three years, whichever comes first, contingent upon the following three
conditions.
폷 Documentation verifies a 10% fleet oil sampling with results that are below the guidelines specified in Section 1.
폷 There is a minimum of six magnets in the housing. Meritor 61163/71163 drive axles come standard with six magnets in the housing.
폷 Approved extended-drain interval lubricants are used according to TP-9539, Approved Rear Drive Axle Lubricants. (Drive axles excluded are
RC-26-633/634 and RC-26/27-720.)
146
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8 Rear Drive Axles
Table BY: Single Rear Drive Axle Oil Capacities
Axle Model
A-150
B-100
B-140
B-150
C-100
D-100
D-140
E-100
E-105
E-150
F-100
F-106
F-120
F-121
F-140
G-161
H-100
H-140
H-150
H-162
H-170
H-172
L-100
L-140
L-155
L-172
M-172
Q-100
Q-145
QT-140
R-100
R-140
R-155
R-160
R-163
R-170
R-270
RL-170
RC-22-145
RC-23-160
RC-25-160
RS-13-120
Oil Capacity*
Pints
5.5
10.0
12.0
3.5
12.5
12.5
12.5
15.0
12.5
9.0
13.0
13.0
15.0
15.0
14.0
21.0
20.0
21.0
11.0
20.0
27.0
27.0
23.0
24.0
24.0
27.0
27.0
31.0
24.0
24.0
30.0
28.0
28.0
28.0
34.0
43.0
55.0
48.0
32.3
41.0
39.5
18.4
Liters
2.6
4.7
5.7
1.7
5.9
5.9
5.9
7.1
5.9
4.3
6.2
6.2
7.1
7.1
6.6
9.9
9.5
9.9
5.2
9.5
12.8
12.8
10.9
11.4
11.4
12.8
12.8
14.7
11.4
11.4
14.2
13.3
13.3
13.3
16.1
20.3
26.0
22.7
15.3
19.4
18.7
8.7
Axle Model
RS-15-120
RS-15-210
RS-15-220
RS-17-140
RS-17-144
RS-17-145
RS-17-220
RS-17-224
RS-19-144
RS-19-145
RS-19-220
RS-19-224
RS-21-145
RS-21-160
RS-21-230
RS-23-160
RS-23-161
RS-23-180
RS-23-186
RS-23-240
RS-23-380
RS-25-160
RS-26-160
RS-26-180
RS-26-185
RS-26-380
RS-30-180
RS-30-185
RS-30-380
RS-38-380
S-170
U-140
U-170
U-270
W-170
W-270
59722
59723
59732
59733
59843
61142
61143
Oil Capacity*
Pints
18.4
14.3
30.0
28.6
32.0
33.6
30.7
29.0
32.0
33.2
30.0
29.0
32.3
39.0
38.9
39.5
37.2
47.3
47.3
37.4
63.6
37.0
47.5
46.6
46.0
58.2
46.6
46.0
58.2
53.1
43.0
24.0
43.0
55.0
43.0
55.0
30.5
30.5
30.5
30.5
30.5
42.0
41.0
Liters
8.7
6.8
14.0
13.5
15.0
15.9
14.5
13.0
15.0
15.7
14.0
13.0
15.3
18.0
18.4
18.7
17.6
22.4
22.4
17.7
30.1
17.0
22.5
22.0
22.0
27.5
22.0
22.0
27.5
25.1
20.3
11.4
20.3
26.0
20.3
26.0
14.4
14.4
14.4
14.4
14.4
19.8
19.3
8
* Oil capacities are for standard track axles that have been measured at various common drive pinion angles. The quantities listed include enough oil for both
wheel ends. These oil capacities will change if the track or the drive pinion angle is different.
Meritor Maintenance Manual 1 (Revised 08-06)
147
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8 Rear Drive Axles
Table BZ: Tandem Rear Drive Axle Oil Capacities
Oil Capacity1
Oil Capacity1
Axle Model
Carrier
Pints
Liters
Axle Model
Carrier
Pints
Liters
SQHP
Forward Rear
40.0 36.0
18.9 17.0
MT-40-143MA-N
Forward Rear
30.2 25.8
14.3 12.2
SR-170
Forward Rear
55.0 43.0
26.0 20.3
RT-34-140
Forward Rear
26.0 35.0
12.3 16.6
SRHD
Forward Rear
39.0 36.0
18.5 17.0
RT-34-144
Forward Rear
30.0 25.0
14.0 12.0
SSHD
Forward Rear
34.0 28.0
16.0 13.2
RT-34-145
Forward Rear
29.6 25.4
14.0 12.0
ST-170
Forward Rear
55.0 43.0
26.0 20.3
RT-34-145P
Forward Rear
25.7 23.4
12.1 11.1
STHD
Forward Rear
34.0 28.0
16.0 13.2
RT-40-140
Forward Rear
30.2 22.8
14.3 10.8
SU-170
Forward Rear
55.0 43.0
26.0 20.3
RT-40-145
Forward Rear
30.2 25.8
14.3 12.2
SUHD
Forward Rear
34.0 28.0
16.0 13.2
RT-40-149
Forward Rear
30.0 25.0
14.0 12.0
SW-170
Forward Rear
55.0 43.0
26.0 20.3
RT-40-160
Forward Rear
39.1 39.4
18.5 16.3
RT-40-169
Forward Rear
39.0 34.0
18.0 16.0
RT-44-145
Forward Rear
29.3 25.1
13.9 11.9
RT-46-16HEH/HP
Forward Rear
38.0 33.0
18.0 15.0
RT-46-160
Forward Rear
39.1 34.4
18.5 16.3
RT-46-164
Forward Rear
39.1 39.4
18.5 16.3
Table CA: Oil Quantities for R-170 Axles with and without
RT-46-164EH/P
Forward Rear
38.0 33.0
18.0 15.0
Traction Equalizer®
RT-46-169
Forward Rear
39.0 34.0
18.0 16.0
RT-48-1802
Forward Rear
61.1 36.8
28.9 17.4
RT-48-3802
Forward Rear
61.1 63.6
28.9 30.1
RT-50-160
Forward Rear
38.0 33.0
18.0 15.0
Forward Rear
44.1 41.2
20.9 19.5
Forward Rear
56.1 36.1
26.5 17.1
Forward Rear
56.1 36.1
26.5 17.1
RT-52-380 2
Forward Rear
56.1 58.2
26.5 27.5
2
Forward Rear
56.1 36.1
26.5 17.1
RT-52-160
RT-52-180
2
RT-52-185
RT-58-180
RT-58-185
Forward Rear
56.1 36.1
26.5 17.1
2
Forward Rear
56.1 58.2
26.5 27.5
RT-70-380 2
Forward Rear
54.4 53.1
25.7 25.1
SFHD
Forward Rear
17.0 16.5
8.0 7.8
SL-100
Forward Rear
39.6 37.7
18.7 17.8
SLHD
Forward Rear
32.5 32.0
15.3 15.1
SQ-100
Forward Rear
39.6 37.7
18.7 17.8
SQ-100A
Forward Rear
39.3 37.6
18.6 17.8
SQHD
Forward Rear
34.0 31.0
16.0 14.7
RT-58-380
148
Meritor Maintenance Manual 1 (Revised 08-06)
1
2
Oil capacities are not for standard track axles that have been measured
at various common drive pinion angles. The quantities listed include
enough oil for both wheel ends. These oil capacities will change if the
track or the drive pinion angle is different.
Forward carrier with oil pump system
®
With Traction Equalizer
40 pints oil (18.9 liters) + 3 pints
additive (1.4 liters)
Without Traction
Equalizer®
43 pints oil (20.3 liters)
mm1.fm.book Page 149 Thursday, August 24, 2006 12:29 PM
8 Rear Drive Axles
Table CB: Tridem Rear Drive Axle Oil Capacities
Oil Capacity*
Axle Model
Carrier
Pints
Liters
RZ-166
Axle 1 Axle 2 Axle 3
39.1 39.1 34.4
18.5 18.5 16.3
RZ-186
Axle 1 Axle 2 Axle 3
56.1 39.1 34.4
26.5 18.5 16.3
RZ-188
Axle 1 Axle 2 Axle 3
56.1 56.1 36.1
26.5 26.5 17.1
* Oil capacities are not for standard track axles that have been measured at various common drive pinion angles.
The quantities listed include enough oil for both wheel ends. These oil capacities will change if the track or the drive
pinion angle is different.
Table CC: Rear Drive Axle Oil Specifications
Gear Oil Type
Non-Extended
Drain Lubricants
Extended Drain
Lubricants
Petroleum with
EP Additives
Petroleum with
Extended Drain
Additives
A.P.I.
Specification
SAE Grade
GL-5
GL-5
Meritor
Specification
Military/SAE
Specification
85W/140
O-76-A
80W/140
O-76-B
80W/90
O-76-D
MIL-PRF-2105
E and SAE
J2360
75W/90
O-76-E
Above –40° F (–40° C)
75W
O-76-J
From –40° F (–40° C) to
35° F (2° C)
75W/140
O-76-L
80W/90
—
Outside Temperature
Above +10° F (–12° C)
Above –15° F (–26° C)
Above –15° F (–26° C)
Above –40° F (–40° C)
MIL-PRF-2105
E and SAE
J2360
Above –15° F (–26° C)
8
Semi-Synthetic
80W/90
—
Above –15° F (–26° C)
Full Synthetic
75W/140
O-76-M
Above –40° F (–40° C)
Full Synthetic
75W/90
O-76-N
Above –40° F (–40° C)
Table CD: Limited Slip Friction Modifier Specifications*
Manufacturer
Specification
DSL-178
Guardsman Products
Equa-Torque 2411 and 2414
Sta-Lube Corporation
Lubrizol 6178
Lubrizol Corporation
* For all GL-5 oils, petroleum oil or synthetic, add one of the specified
limited slip friction modifiers.
Meritor Maintenance Manual 1 (Revised 08-06)
149
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8 Rear Drive Axles
Troubleshooting
All Rear Axles
Contaminated Lubricant Found During Preventive Maintenance
Figure 8.18
Visually
inspect the
lubricant.
Indicates
that water
is entering
the axle.
Milky,
Brownish
Lubricant
color?
Silvery
Indicates
metallic
contamination.
Send out a lubrication
sample for analysis.
Advise the owner to
return for the results.
Inspect the
breather.
Clean and prepare the
housing and carrier
flanges. Apply the correct
gasket or silicone.
Install the carrier.
Fill the carrier with
the correct amount
of the specified lubricant.
Breather
clogged?
Yes
If analysis results
indicate wear or
breakdown in the carrier,
refer to the “Differential
Making Noise” diagnostic
flowchart in this publication.
Clean or replace the
breather. A clogged
breather can cause
a seal leak.
No
Test drive the vehicle
to confirm that the
leak is repaired. Return
the vehicle to service.
Inspect the
carrier seals
for leaks.
Seal
leaking?
No
Inspect the
carrier-to-housing
joint for leaks.
Yes
Replace the leaking
seal with a
unitized seal.
Joint
leaking?
No
Inspect the axle housing
welds for cracks or leaks.
If you find weld cracks,
contact Meritor for
repair welding procedures.
Yes
Fill the carrier
with the correct
amount of the
specified lubricant.
Clean the seal area.
Test drive the
vehicle to confirm
that the leak is
repaired. Return the
vehicle to service.
Drain and
inspect the
lubricant.
Remove the
carrier from
the axle.
4000515g
Figure 8.18
150
Meritor Maintenance Manual 1 (Revised 08-06)
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9 Suspensions
Hazard Alert Messages
9 Suspensions
Figure 9.1
CURBSIDE
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
AIR
SPRING
FRAME
BRACKET
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Technical Publications
SHOCK
ABSORBER
How to Obtain Additional Maintenance and
Service Information
Refer to the publications in Table CE. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
LOWER
CONTROL
ARM
ROADSIDE
Table CE: Publications
Model
Manual
Trailer Axles
Maintenance Manual 14
RideStar™ RFS Series Trailer
Air Suspension Systems
Maintenance Manual 14F
RideStar™ RHP Series
Single-Axle Trailer Air
Suspension System
Maintenance Manual 14L
RideStar™ RHP Series
Sliding Tandem Trailer Air
Suspension System
Maintenance Manual 14S
Trailer Axles
Failure Analysis Manual
TP-0445
AXLE SHOWN WITH
OPTIONAL X-30
BRAKE DRUMS
AXLE
ASSEMBLY
4003726c
Figure 9.1
Components
앫 Frame brackets
앫 Upper and lower control arms
앫 Axle assembly
앫 Air springs
앫 Shock absorber
9
Features
앫 A compact 20,000 lb (9072 kg) capacity trailer air suspension
system.
RideStarTM RHP Series Trailer Air
Suspension Systems
앫 A nominal ride height of 16.5 and 17.5-inches (41.9-44.4 cm)
with eight-inches (20.3 cm) of total travel, three-inches (7.6 cm)
jounce and five-inches (12.7 cm) of rebound.
Single-Axle System
앫 An air system option is available when transporting the trailer by
rail car.
The Meritor RideStar™ RHP Series single-axle trailer air suspension
system centers around a stabilized parallelogram design that
incorporates a single unified frame bracket. The upper and lower
control arms are parallel to each other. The air springs mount
directly over the axle. Figure 9.1.
Meritor Maintenance Manual 1 (Revised 08-06)
151
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9 Suspensions
Identification
Sliding Tandem System
The identification tag is located on the front of the roadside frame
bracket. Figure 9.2.
The Meritor RideStar™ RHP sliding tandem trailer air suspension
system centers around a stabilized parallelogram design that
incorporates a single unified frame bracket. The upper and lower
control arms are parallel to each other. The air springs mount
directly over the axle. Figure 9.4.
Figure 9.2
ID TAG
LOCATION
Figure 9.4
SLIDER
ASSEMBLY
FRAME
BRACKET
UPPER
CONTROL
ARM
CURBSIDE
ROADSIDE
0000000a
FOR SUSPENSION NOMINAL RIDE HEIGHT
(NRH), REFER TO THE NRH VALUE INDICATED
ON THIS LABEL. FOR THE ACTUAL RIDE
HEIGHT VALUE, REFER TO THE VEHICLE/
TRAILER MANUFACTURER'S SPECIFICATION.
SUSP. CAP.
C
A
LB.
NRH
D
MODEL
B
IN.
SERIAL NO.
AIR
SPRING
STAMPED INFORMATION
A
B
C
D
Suspension Capacity
Nominal Ride Height
Model Number
Serial Number
ROADSIDE
4003731a
AXLE
ASSEMBLIES
Figure 9.2
The model number on the identification tag provides suspension and
axle information. Figure 9.3.
SHOCK
ABSORBER
LOWER
CONTROL
ARMS
AXLE SHOWN
WITH OPTIONAL X-30
BRAKE DRUMS
Figure 9.4
Components
Figure 9.3
앫 Frame brackets and slider assembly
Model Number Example
앫 Upper and lower control arms
RHP55 TN 1805
Sequence Number: Can
be cross referenced
to the Bill of Material.
Axle Model
4003732a
152
Meritor Maintenance Manual 1 (Revised 08-06)
앫 Air springs
앫 Shock absorbers
Suspension Model
Figure 9.3
앫 Axle assemblies
4002667d
mm1.fm.book Page 153 Thursday, August 24, 2006 12:29 PM
9 Suspensions
Features
Figure 9.6
앫 A compact 37,600 lb (17 055 kg) capacity tandem trailer air
suspension and slider system designed for sliding tandems.
Model Number Example
RHP11 TN 1805
앫 A nominal ride height of 16.5-18.5-inches (41.9-47.0 cm) with
eight-inches (20.3 cm) of total travel, three-inches (7.6 cm)
jounce and five-inches (12.7 cm) of rebound.
Sequence Number: Can
be cross referenced
to the Bill of Material.
앫 A mounting height of 24.5-26.5-inches (62.2-67.3 cm).
Axle Model
앫 An air system option is available when transporting the trailer by
rail car.
Suspension Model
4002671b
Identification
Figure 9.6
The identification tag is located on the roadside of the suspension
near the pin release handle. Figure 9.5.
Single-Axle and Sliding Tandem
Suspensions
Figure 9.5
OLD STAMPED
ID LOCATION
Inspection
CURRENT ID
TAG LOCATION
Inspect the suspension, air suspension components, height control
valve and axle at regular intervals during normal operation and each
time the trailer is serviced.
앫 Before each trip, visually inspect the system. Listen for air leaks.
After 1,000 Miles (1600 km) and Annually Thereafter
ROADSIDE
WARNING
FOR SUSPENSION NOMINAL RIDE HEIGHT
(NRH) , REFER TO THE NRH VALUE INDICATED
ON THIS LABEL. FOR THE ACTUAL RIDE
HEIGHT VALUE, REFER TO THE VEHICLE/
TRAILER MANUFACTURER'S SPECIFICATION
SUSP. CAP.
C
A
LB.
NRH
D
MODEL
B
IN.
SERIAL NO.
STAMPED INFORMATION
A
B
C
D
Suspension Capacity
Nominal Ride Height
Model Number
Serial Number
4002668b
Check fastener torque values, tighten loose fasteners and
replace damaged fasteners. Loose, damaged or missing
fasteners can cause loss of vehicle control, serious personal
injury and damage to components.
1.
Inspect all nuts and bolts for looseness or movement. Tighten
loose fasteners to the correct torque. Refer to Maintenance
Manual 14L, RideStar™ RHP Series Single-Axle Trailer Air
Suspension System; and Maintenance Manual 14S,
RideStar™ RHP Series Sliding Tandem Trailer Air Suspension
System, for the correct torque specifications. Thereafter,
inspect the suspension each time the trailer is serviced.
2.
Check for looseness of the alignment pivot bolts. If the bolts
are loose, realign the axles prior to retightening the bolts.
3.
Replace damaged fasteners to maintain the correct torque
specifications and to comply with warranty requirements.
Figure 9.5
The model number on the identification tag provides suspension and
axle information. Figure 9.6.
Meritor Maintenance Manual 1 (Revised 08-06)
153
9
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9 Suspensions
Maintenance
Figure 9.7
Single-Axle and Sliding Tandem
Suspensions
1.
Inspect for loose, broken or missing fasteners. Repair or
replace as needed.
2.
Inspect the welds for cracks at the axle, frame bracket and
upper control arm crosstube.
3.
Inspect the bushings for ragged or loose pieces that can protrude
from the connection area. Use a two-foot (61 cm) pry bar to
check for looseness or free play. Also refer to Upper Control Arm
Bushing Periodic Inspection Guidelines: All RideStar™ RHP
Series Trailer Air Suspension Systems in this section.
UPPER
CONTROL
ARM
앫 If looseness or free play exceeds 0.062-inch (1.6 mm)
vertical play: Contact the ArvinMeritor Customer Service
Center at 800-535-5560.
4.
Inspect the flex member of the air springs for cuts and
abrasions. Replace the air spring if it is cut or damaged.
5.
Check for obstructions or interference to the air spring surface
that can damage the air spring. Relocate and secure items,
such as air hoses, that can contact the air spring.
UPPER
AXLE
SEAT
FRAME
BRACKET
LOWER
AXLE
SEAT
LOWER
CONTROL
ARM
ROADSIDE
4003735a
SINGLE-AXLE TRAILER SUSPENSION
Figure 9.7
6.
Check for leaks in the air lines at the air spring bead plate,
piston and mounting studs. Replace air lines, fittings or air
springs that leak.
7.
Inspect the shock absorbers for worn bushings, oil leaks and
dents. Check that the mounting holes have not enlarged.
8.
After normal operation, check the shock absorbers for heat.
앫 Warm shock absorbers most likely indicate that the shock
absorbers are operating correctly.
앫 Cold shock absorbers can indicate that the shock absorbers
are not operating correctly and must be replaced. Replace
the shock absorbers as necessary.
9.
Figure 9.8
UPPER
AXLE SEAT
UPPER
CONTROL
ARM
FRAME
BRACKET
Inspect the structure of the suspension. Figure 9.7 and
Figure 9.8. Inspect the following items.
LOWER
CONTROL
ARMS
앫 Upper axle seats
앫 Upper control arms
앫 Lower axle seats
앫 Lower control arms
앫 Axle welds
앫 Brake interference, cam or chamber
앫 Frame brackets
앫 Shock absorber brackets
154
Meritor Maintenance Manual 1 (Revised 08-06)
ROADSIDE
SLIDING TANDEM TRAILER SUSPENSION
Figure 9.8
LOWER
AXLE SEAT
4002673a
mm1.fm.book Page 155 Thursday, August 24, 2006 12:29 PM
9 Suspensions
Upper Control Arm Bushing Periodic
Inspection Guidelines: All RideStar™
RHP Series Trailer Air Suspension Systems
5.
Inspect the upper control arm and bushing for the following
conditions.
A.
Meritor recommends conducting a visual inspection of the
RideStar™ RHP Series air suspension system whenever routine
maintenance is performed. The purpose of the inspection is to
determine the condition of the two-piece urethane bushings located
within the upper control arm bushing tubes. Being aware of certain
wear trends of this part will ensure that excessive wear to the upper
control arm, frame bracket and axle seat does not occur causing the
component to be replaced.
If the position is correct, insert a two-foot (0.61 m) pry bar
between the upper control arm and the bottom of the axle
seat to measure the free play gap.
앫 If the bushing free play gap exceeds 1/16-inch
(1.588 mm) at either the axle seat or the frame
bracket: Replace the bushings. Note: Even if the free
play gap exceeds the specification for one bushing,
you must replace all eight bushings at the next
available opportunity.
Follow these instructions to inspect the upper control arm bushings
without performing disassembly procedures underneath the trailer.
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform trailer maintenance or service.
Park the trailer on a level surface. Block the wheels to prevent
the trailer from moving, which can cause serious personal
injury and damage to components.
1.
Wear safe eye protection.
2.
Park the trailer on a level surface. Block the wheels to prevent
the trailer from moving.
3.
4.
You do not need to lift the tires off the ground. Do not remove
the tires.
Use a flashlight to visually inspect all eight upper control arm
bushings to determine bushing condition.
The bushing flanges are intact on both sides of the
bushing tube, and everything is centered within the frame
bracket or axle seat, which is the correct position for the
upper control arm and bushing. Figure 9.9.
앫 If the bushing free play gap is less than 1/16-inch
(1.588 mm) for all the bushings: The bushings are
not worn. Do not replace the bushings.
B.
The upper control arm and bushing have shifted slightly to
one side. The bushing flange is worn, torn or missing. You
don’t find significant wear between the upper control arm
and the frame bracket or axle seat. The free play gap is
less on one side than the other side. Figure 9.10.
앫 If you find these conditions: Replace the bushing at
the next available opportunity.
C.
The upper control arm and bushing have shifted and
clamped to one side. The bushing flange is missing on
one side. The upper control arm is pinned against the
frame bracket. Significant wear exists between the upper
control arm and the frame bracket or axle seat. There is
no free play gap on one side, and a large gap on the other
side. Figure 9.11.
앫 If you find these conditions: Replace the bushing
immediately to prevent damage to components.
Meritor Maintenance Manual 1 (Revised 08-06)
155
9
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9 Suspensions
Slider on Sliding Tandem Suspension
System
Figure 9.9
The gap on both sides
should be equal.
UPPER CONTROL
ARM BUSHING
TUBE
URETHANE
BUSHING
FLANGES
FRAME
BRACKET
1.
Inspect for loose, broken or missing fasteners. Repair or
replace as needed.
2.
Check the slider locking pins, slider pull-bar mechanism and
slider wear pads for signs of excessive wear or binding.
Figure 9.12. Repair or replace as needed.
3.
Inspect the structure of the slider box and crossmembers for
damage. Repair as needed.
4.
Inspect the front and rear hold down clips to ensure that they
are secured correctly around the body rails.
4005368a
Figure 9.9
Figure 9.12
Figure 9.10
The urethane
bushing flange
is worn, torn
or missing.
URETHANE
BUSHING FLANGE
WEAR
PAD
UPPER
CONTROL ARM
BUSHING
TUBE
The gap is less on one side
than the other.
4005369a
LOCKING
PINS ASSEMBLY
Figure 9.10
SLIDER PIN
RELEASE
HANDLE
Figure 9.11
The urethane bushing flange is missing
on one side and the upper control arm
is pinned against the frame bracket.
UPPER
CONTROL ARM
BUSHING
TUBE
There is no gap on one side and a
large gap on the other side.
Figure 9.11
Meritor Maintenance Manual 1 (Revised 08-06)
LOCKING
PIN
HOLD
DOWN
CLIP
4002672c
URETHANE
BUSHING
FLANGE
156
WEAR
PAD
4005370a
Figure 9.12
mm1.fm.book Page 157 Thursday, August 24, 2006 12:29 PM
9 Suspensions
RideStarTM RFS Series Trailer Air
Suspension System
The Meritor RideStar™ RFS Series air suspension system is
designed with trailing arms mounted onto the axle, parallel to each
other and perpendicular to the axle. A pivot bushing, hanger
assembly and alignment collars are mounted to the front of each
trailing arm. The rear of the trailing arm supports the air spring.
Figure 9.13.
Figure 9.13
CONCENTRIC
ALIGNMENT
COLLAR TRAILING ARM
SHOCK
AND AXLE
ABSORBER
SUBASSEMBLY
HANGER
ASSEMBLY
ECCENTRIC
ALIGNMENT
COLLAR
Ride Height
Ride height is the distance from the centerline of the axle to the
underside of the trailer frame. Figure 9.15.
Figure 9.15
TRAILER
FRAME
LOADED
DECK
HEIGHT
RIDE
HEIGHT
CENTER
OF
AXLE
TIRE
STATIC
LOADED
TIRE
RADIUS
LOADED
FRAMETOGROUND
4000948a
Figure 9.15
CURBSIDE
AIR SPRINGS
4000946b
All Meritor air suspensions are designed to operate at a specific ride
height, which must be maintained during the life of the suspension.
Otherwise incorrect loading can occur, which can affect suspension
performance, shorten component life and void the Meritor warranty.
Operating a vehicle with ride height higher than specified by the
application can cause the trailer to be over the legal height limit,
depending on the type of trailer and payload.
Figure 9.13
Model Nomenclature
An identification tag is located on the rear of the roadside trailing
arm. To obtain replacement parts, refer to the Service Notes page at
the beginning of this manual and specify the model number on the
tag. Figure 9.14.
To obtain the correct ride-height specification, check the
suspension’s identification tag located on the rear of the ROADSIDE
trailing arm. Also refer to Model Nomenclature.
How to Determine the Correct Ride Height
9
Consider the following factors when you determine the correct
suspension ride height.
Figure 9.14
RFS 23 E T 14 L XXXX
SEQUENTIAL BILL OF
MATERIAL NUMBER
BRAKES
Q = Q Brakes
L = Q+ Brakes
If a variation of suspension ride height is required at each location,
contact ArvinMeritor’s Customer Service Center at 800-535-5560
for assistance.
SUSPENSION’S DESIGNED
RIDE HEIGHT
Example: 14 = 14" Ride Height
SUSPENSION PROFILE
T = High Ride Height Model
UNITS
E = US Standard
M = Metric
SUSPENSION CAPACITY
Example: 23 = 23,000 Pounds
RIDESTARTM FABRICATED
SUSPENSION
4000962c
Figure 9.14
Meritor Maintenance Manual 1 (Revised 08-06)
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9 Suspensions
Frame-to-Ground Distance
Figure 9.18
UNLOADED
TRAILER
FRAME
You must measure the distance from the bottom of the trailer frame
to the ground at each suspension location. Figure 9.16. This
measurement determines the required trailer deck height.
DECK
HEIGHT
Figure 9.16
FRAME-TO-GROUND
LOADED
FRAME-TO-GROUND
UNLOADED
4000949a
Figure 9.18
FRAME-TO-GROUND
4000947a
Figure 9.16
Trailer Deck Height
To calculate the required suspension ride height, subtract the tire’s
static loaded radius from the loaded frame-to-ground dimension.
Figure 9.15.
Auxiliary Air Suspension Lift Axles (Loaded
Frame-to-Ground)
You must determine the loaded frame-to-ground measurement of
auxiliary air suspension lift axles at each suspension location.
Figure 9.19. A leaf-spring suspension’s ride height changes under
various loads and the auxiliary lift axles must be spec’d to meet the
ride height of the loaded leaf-spring suspension for correct operation.
Figure 9.19
AUXILIARY "LIFT" SUSPENSION
Fifth-Wheel Height
DECK
HEIGHT
A trailer frame’s fifth-wheel height can affect the slope of the trailer
frame. For example, a low fifth-wheel height will cause the trailer
frame to slope DOWNWARD toward the front. Determine the correct
ride height at each suspension. Figure 9.17.
LOADED
FRAME-TO-GROUND
LOADED RIDE
HEIGHT
4000947c
Figure 9.17
Figure 9.19
AUXILIARY "LIFT" SUSPENSION
DECK
HEIGHT
LOADED
FRAME-TO-GROUND
LOADED RIDE
HEIGHT
Jounce and Rebound
Jounce is the amount of upward axle travel from the suspension’s
designed ride-height position. Figure 9.20.
Rebound is the amount of downward axle travel from the
suspension’s designed ride-height position. Figure 9.20.
4000947c
Figure 9.20
Figure 9.17
JOUNCE
Trailer Frame Deflection
When the suspension was installed, ride height was determined
without a load on the trailer. Trailer frame deflection can occur when
the trailer is loaded and will change ride height. Be sure to allow for
frame deflection when you determine the correct ride height at each
suspension. Figure 9.18.
RIDE
HEIGHT
CENTERLINE
OF
AXLE
REBOUND
4000948b
Figure 9.20
158
Meritor Maintenance Manual 1 (Revised 08-06)
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9 Suspensions
Tire Clearance
Figure 9.22
2" MINIMUM
LATERAL TIRE
CLEARANCE
REQUIRED
Meritor air suspensions require a 1.5-inch (38 mm) minimum tire
clearance between the top of the tire and the bottom of the trailer
frame structure above the tire when the suspension is at full jounce.
Figure 9.21.
TIRE
TRAILER
FRAME
Figure 9.21
TIRE
CLEARANCE
4000950a
RIDE
HEIGHT
Figure 9.22
Maintenance
TIRE
4000948c
Figure 9.21
How to Determine Tire Clearance
Determine tire clearance by adding the specified tire clearance to
the suspension jounce. This sum is the distance required between
the top of the tire and the bottom of the trailer frame when the
suspension is at its designed ride height.
Example
앫 Jounce = 3-inches (76 mm)
Inspect air suspension components, the height control valve and
axle at regular intervals during normal operation and each time the
trailer is serviced.
Before each trip, visually inspect the suspension system and listen
for any air leaks.
Replace damaged fasteners to maintain correct torque value
specifications and comply with warranty requirements.
Perform the following inspections after the first 1,000 miles
(1600 km) of operation and annually thereafter.
1.
Check fastener torque values, tighten loose fasteners and
replace damaged or missing fasteners.
2.
Visually inspect all nuts and bolts for looseness and movement.
Figure 9.23. Tighten loose fasteners to the correct torque
values. Thereafter, inspect the suspension components each
time the trailer is serviced.
3.
Check for loose pivot bolts.
앫 Tire Clearance = 1.5-inches (38 mm)
Calculation
3-inches (76 mm) + 1.5-inches (38 mm) = 4.5-inches (114 mm) =
Space required above the tire at ride height
A two-inch (51 mm) clearance is required between the inside of the
tire and the trailer frame on each side. This clearance allows for
both lateral movement of the suspension and tire deflection.
Figure 9.22.
앫 If the bolts are loose: Align the axles before tightening
the bolts.
Meritor Maintenance Manual 1 (Revised 08-06)
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9 Suspensions
Figure 9.23
TOP VIEW
1
2
1.
Inspect for broken and missing fasteners. Repair or replace as
needed.
2.
Inspect welds for cracks at the trailing arm and axle
subassembly and hanger assemblies.
3.
Inspect the flexmember of the air springs for any cuts and
abrasions. Replace the air spring immediately if it is cut or
damaged.
4.
Check for obstructions and interference at the air springs that
may cause scuffing and abrasions. Relocate and secure items
such as air hoses that can contact any part of the air spring.
5.
Check for leaks in the air lines, at the air spring upper bead
plate, piston and mounting studs. Figure 9.24. Replace leaking
air lines, fittings or air springs.
3
4
5
6
7
8
Figure 9.24
SIDE VIEW
UPPER
BEAD
PLATE
UPPER AIR SPRING
COMBINATION,
MOUNTING AND
AIR INLET,
STUD (3/4-16 NF)
9
9
FLEXMEMBER
REAR VIEW
PISTON
LOWER AIR
SPRING MOUNTING
STUD (1/2-13 NC)
4000952a
Figure 9.24
10
10
4000951c
6.
Inspect the structure of the following air suspension
components. Figure 9.25.
앫 Hanger assemblies
Figure 9.23
앫 Trailing arm and axle subassembly
Item
Description
앫 Shock mountings
1
Curbside Lower Shock Bolt
2
Curbside Pivot Bolt
앫 Axle-to-trailing arm connection
3
Curbside Upper Shock Bolt
4
Roadside Upper Shock Bolt
앫 Hanger assembly bracing at interface points
5
Roadside Pivot Bolt
앫 Pivot connections
6
Roadside Lower Shock Bolt
7
Height Control Valve Mounting Bolts
8
Height Control Valve and Linkage
9
Upper Air Spring Nut(s)
10
Lower Air Spring Nut(s)
160
Meritor Maintenance Manual 1 (Revised 08-06)
앫 Brake interference, cam or chamber
mm1.fm.book Page 161 Thursday, August 24, 2006 12:29 PM
9 Suspensions
What to Look for and Actions Required
Figure 9.25
HANGER
ASSEMBLY
TRAILING ARM
AND AXLE
SUBASSEMBLY
PIVOT
CONNECTION
SHOCK
ABSORBER
MOUNTINGS
AXLE-TO-TRAILER
ARM CONNECTION
4000953b
Figure 9.25
Actions Required
Washers ARE NOT installed at
the upper and lower shock
absorber pivot connections,
and bushing migration IS NOT
evident.
Install new washers (Meritor
part number 1229-M-4979).
Washers ARE NOT installed at
the upper and lower shock
absorber pivot connections,
and bushing migration IS
evident.
Install a replacement shock
absorber (Meritor part number
A-7805-L-1026) with new
washers (Meritor part number
1229-M-4979).
Installing the New 2-1/4-inch O.D. (57.15 mm)
Washers Without Replacing the Shock Absorber
Inspect the Shock Absorbers
1.
What to Look for
Check the shock absorber bushings for looseness and wear.
Inspect the shock absorbers for oil leaks and dents. Replace
worn or damaged shock absorbers. Figure 9.26.
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Figure 9.26
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only
by jacks. Jacks can slip and fall over. Serious personal injury
and damage to components can result.
SHOCK ABSORBER
TOP MOUNTING
Verify that all personnel are clear of the trailer before you
inflate or deflate the air springs. The air suspension system
has various pinch points that can cause serious personal
injury.
SHOCK ABSORBER
BOTTOM MOUNTING
4000957a
1.
Wear safe eye protection.
2.
Park the trailer on a level surface. Block the wheels to prevent
the trailer from moving. Correctly support the trailer.
3.
Remove the 7/8-inch (22.23 mm) nut and 7/8-inch x
1-3/4-inch O.D. (22.23 x 44.45 mm) washer from the UPPER
shock absorber mounting. Discard the washer. Do not remove
the existing washer on the shock absorber bolt. Figure 9.27.
Figure 9.26
2.
Inspect the shock absorbers to determine that washers are
installed at the shock absorber upper and lower pivot
connections, and shock absorber bushing migration is evident.
Refer to the following procedure.
9
Meritor Maintenance Manual 1 (Revised 08-06)
161
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9 Suspensions
Figure 9.27
Figure 9.29
Discard this
washer.
Retain the
nut and
washer.
Retain this
washer.
Retain
the nut.
Discard the
washer.
EXISTING UPPER MOUNT
EXISTING LOWER MOUNT
4000958b
4000959b
Figure 9.27
Figure 9.29
4.
Install the new 7/8-inch x 2-1/4-inch O.D. (22.23 x 57.15 mm)
washer between the shock tube and shock absorber. Install the
new, larger washer between the shock absorber and locknut.
Hand-tighten the nut. Figure 9.28.
6.
Remove and discard the 7/8-inch x 1-3/4-inch O.D.
(22.23 x 44.45 mm) washer on the shock absorber bolt.
7.
Install the new 7/8-inch x 2-1/4-inch O.D. (22.23 x 57.15 mm)
washer between the bolt head and shock absorber. Install a
new, larger washer between the shock absorber and the shock
tube. Figure 9.30.
Figure 9.28
INBOARD SIDE
OUTBOARD SIDE,
WHEEL END
NEW 7/8" X 2-1/4"
(22.23 x 57.15 MM)
FLAT WASHERS
CURBSIDE
HANGER
ASSEMBLY
Figure 9.30
INBOARD SIDE
OUTBOARD SIDE,
WHEEL END
SHOCK
ABSORBER
7/8" X 1-3/4"
(22.23 X
44.45 MM)
FLAT WASHER
EXISTING 7/8"
(22.23 MM)
LOCKNUT
SHOCK
ABSORBER
NEW UPPER MOUNT
7/8"
(22.23 MM)9 X 11"
SHOCK
BOLT
7/8"
(22.23 MM)9 X 11"
SHOCK BOLT
162
Remove the 7/8-inch (22.23 mm) nut and 7/8-inch
x 1-3/4-inch O.D. (22.23 x 44.45 mm) washer from the
LOWER shock absorber mounting. Do not discard this washer.
Figure 9.29.
Meritor Maintenance Manual 1 (Revised 08-06)
7/8" X 1-3/4"
(22.23 X 44.45 MM)
FLAT
WASHER
4000958a
NEW 7/8" X 2-1/4"
(22.23 X 57.15 MM)
FLAT WASHERS
NEW LOWER MOUNT
Figure 9.28
5.
TRAILING
ARM
7/8"
(22.23 MM)-9
LOCKNUT
4000959a
Figure 9.30
8.
Install the washer and locknut. Hand-tighten the nut.
mm1.fm.book Page 163 Thursday, August 24, 2006 12:29 PM
9 Suspensions
9.
Verify that the suspension is at the correct ride height.
Refer to Maintenance Manual 14F, RideStar™ RFS Series
Trailer Air Suspension Systems, for ride height instructions.
10. Tighten the nuts at the upper and lower shock absorber
mountings to 350-400 lb-ft (465-542 N폷m). @
Installing a Replacement Shock Absorber and
New 2-1/4-inch O.D. (57.15 mm) Washers
1.
Wear safe eye protection.
2.
Park the trailer on a level surface. Block the wheels to prevent
the trailer from moving. Correctly support the trailer.
3.
Remove the 7/8-inch (22.23 mm) nut and 7/8-inch x
1-3/4-inch O.D. (22.23 x 44.45 mm) washer from the UPPER
shock absorber mounting. Discard the washer. Figure 9.27.
4.
Remove the 7/8-inch (22.23 mm) nut and 7/8-inch x
1-3/4-inch O.D. (22.23 x 44.45 mm) washer from the LOWER
shock absorber mounting. Remove the lower bolt and washer
from the shock absorber. Discard the washer that’s under the
bolt head. Figure 9.29.
5.
Remove the shock absorber from the upper bolt.
6.
Install the new 7/8-inch x 2-1/4-inch O.D. (22.23 x 57.15 mm)
washer onto the upper shock absorber bolt between the shock
tube and the shock absorber. Install the larger-diameter
washer and locknut. Hand-tighten the nut. Figure 9.28.
7.
Install the new 7/8-inch x 2-1/4-inch O.D. (2.23 x 57.15 mm)
washer onto the lower shock absorber bolt. Install the shock
absorber, then the larger washer between the shock absorber
and shock tube. Install the washer and locknut. Hand-tighten
the nut. Figure 9.30.
8.
Verify that the suspension is at the correct ride height. Refer to
Maintenance Manual 14F, RideStar™ RFS Series Trailer Air
Suspension Systems, for ride height instructions.
9.
Tighten the nuts at the upper and lower shock absorber
mountings to 350-400 lb-ft (465-542 N폷m). @
9
Meritor Maintenance Manual 1 (Revised 08-06)
163
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10 Trailer Axles
Important Information
10 Trailer Axles
Meritor automatic slack adjusters (ASAs) should not need to be
manually adjusted in service. ASAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ASA,
brake actuator or other system components.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ASA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
For Meritor brake adjustment, refer to the brake adjustment tables
in this manual. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
Hazard Alert Messages
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
Description
Axle Models
Meritor trailer axle models fall into three categories.
앫 Conventional axles currently in production, such as TN, TP, TQ,
TR, TQC, TQD and TRD models. These axle models are available
either for installation on new trailers or as service replacement
parts.
앫 Conventional axles no longer in production, such as TK, TKN, RN
and RQ models. These axle models are available only as service
replacement parts.
앫 TB Series axles with unitized wheel-end assemblies. These
axles provide a low-maintenance alternative to conventional
wheel ends.
Axle Designs
Beams
Straight beams, such as the TN, TP, TQ and TR models. Figure 10.1.
Figure 10.1
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle service or maintenance.
Technical Publications
How to Obtain Additional Maintenance and
Service Information
Refer to the publications in Table CF. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
4002695a
Figure 10.1
Crank beams, such as the TQC model. Figure 10.2.
Figure 10.2
Table CF: Publications
Model
Manual
Trailer Axles
Maintenance Manual 14
Trailer Axles with Unitized
Wheel Ends
MM-0420
Meritor Tire Inflation Systems
Maintenance Manual 14P
Trailer Axles
Failure Analysis Manual TP-0445
4002696a
164
Meritor Maintenance Manual 1 (Revised 08-06)
Figure 10.2
mm1.fm.book Page 165 Thursday, August 24, 2006 12:29 PM
10 Trailer Axles
Drop center beams, such as the TQD and TRD models. Figure 10.3.
TB Series Trailer Axles with Unitized
Wheel-End Assemblies
Figure 10.3
CAUTION
4002697a
Figure 10.3
Beam Cross Sections
앫 Round
앫 Rectangular (available only as service replacement beams)
TB series trailer axles with unitized wheel-end assemblies use
conventional brakes and automatic slack adjusters, as well as
conventional tire and wheel assemblies. Service these
components as you would under normal operating conditions
to avoid damage to components.
A unitized wheel end is permanently sealed and lubricated as
an assembly. Do not attempt to remove the hub bearings, seals
and lubricant. You cannot service these components. Damage
to components can result.
NOTE: Removal of the long-life bearings, seals and lubricant from
the hub assembly will void the warranty.
Spindle Designs
앫 The TN/TQ Series axles use the most common wheel bearings in
the trailer industry.
앫 The TR Series axles use wheel bearings compatible with drive
axles.
앫 The TP Series axles use bearings compatible with Fruehauf
axles.
앫 The TB Series axles use unitized bearings.
Brakes
앫 Q and Q Plus™ brakes
®
앫 Stopmaster wedge brakes
앫 Dura-Master® and DiscPlus™ air disc brakes
The TB series trailer axle features a permanently-sealed and
lubricated unitized wheel-end assembly designed to help reduce
wheel-end maintenance.
The unitized wheel end is designed to remain in place on the axle for
a minimum of five years or 500,000 miles (800 000 km).
For TB series unitized wheel-end service procedures, refer to
Maintenance Manual MM-0420, Trailer Axles with Unitized Wheel
Ends. To obtain this publication, refer to the Service Notes page on
the front inside cover of this manual.
Unitized Wheel Ends and Conventional Wheel Ends
On a unitized wheel end, you install the hub, seal, lubricant and
bearings onto the axle spindle as an assembly. Figure 10.4.
Figure 10.4
10
AXLE SPINDLE
UNITIZED HUB ASSEMBLY
1003332a
Figure 10.4
Meritor Maintenance Manual 1 (Revised 08-06)
165
mm1.fm.book Page 166 Thursday, August 24, 2006 12:29 PM
10 Trailer Axles
On a conventional wheel end, you install the hub, seal, lubricant and
bearings onto the axle spindle as separate components.
Figure 10.5.
Figure 10.5
OUTER
BEARING CUP
INNER
LUBRICANT
BEARING CUP
INNER
BEARING CONE
How to Find the Model Number, Serial
Number and Date of Manufacture
Effective July 2004, Meritor now engraves the axle model number,
serial number and date of manufacture onto the center of the trailer
axle beam. Figure 10.6. Previously Meritor affixed an aluminum tag
to the center of the axle beam that includes this information.
Figure 10.7.
Figure 10.6
OUTER
BEARING CONE
HUB
OIL
SEAL AXLE
SPINDLE
1003333a
Figure 10.5
How to Identify Trailer Axles with Unitized
Wheel Ends
Removal of long-life bearings, seals or lubricant from the Meritor TB
series trailer axle hub will void the warranty. Refer to Maintenance
Manual MM-0420, Trailer Axles with Unitized Wheel Ends, or call
ArvinMeritor’s Customer Service Center at 800-535-5560 for
information.
FRA04161115
06/14/03
MERITOR
P/N TN4671Q636Q
S/N FRA04161115
DATE 06/15/04
CURRENT
ALUMINUM TAG
NEW ENGRAVED
IDENTIFICATION
TQ 4671Q 9115
4005391a
Figure 10.6
Figure 10.7
앫 The model number designation for the TB series is prefixed with
TB; for example, TB-4670 or TB-8670.
앫 The axle spindles are shorter with a single journal.
MODEL TN 4670 Q 2020
앫 The hubs contain non-serviceable bearings, seals and lubricant.
SERIAL NO. KNA 38050685
DATE 27693
앫 The hubcaps screw onto the axle spindle and have no provisions
for adding lubricant.
앫 The axle spindle retention hardware features a thicker inner nut
and a bendable tab lock washer.
앫 Warranty information is stamped on each unitized wheel-end
hubcap.
166
Meritor Maintenance Manual 1 (Revised 08-06)
KENTON, OHIO 43326
Figure 10.7
4002698a
mm1.fm.book Page 167 Thursday, August 24, 2006 12:29 PM
10 Trailer Axles
What the Numbers Mean
Model Number
The model number contains letters and digits (for example,
TN 4670 Q 2020); and identifies the axle assembly. You’ll need the
model number to obtain replacement parts.
Also refer to the Current Product Model Numbers chart in this
section and Figure 10.7.
Serial Number
The serial number is a Meritor internal control number; for example,
KNA 38050685.
Date of Manufacture
The date of manufacture is a Julian date; for example, 27693.
앫 The first three digits (276) indicate the 276th day of the year:
October 3.
앫 The last two digits (93) indicate the year: 1993.
Model Nomenclature
Current Production Model Numbers
Model numbers for Meritor trailer axles are composed of letters and
digits; for example, TQD 4670 Q 52. These letters and digits
indicate the weight capacity and type of components installed on the
axle. For a more comprehensive list of Meritor current production
trailer axle models, refer to publication TP-8301, Trailer Axle
Specifications.
Meritor aftermarket model numbers differ from the current
production model numbers detailed in Figure 10.8. Refer to parts
catalog PB-8857, Brake, Trailer Axle and Wheel-Attaching Parts, for
a chart detailing these numbers. To obtain these publications, refer
to the Service Notes page on the front inside cover of this manual.
10
Meritor Maintenance Manual 1 (Revised 08-06)
167
mm1.fm.book Page 168 Thursday, August 24, 2006 12:29 PM
10 Trailer Axles
Figure 10.8
CURRENT PRODUCTION MODEL NUMBERS
Design Variation➀
C = Crank
D = Drop
Blank = Straight
Brake Diameter
2 = 12.25" (31 cm)
5 = 15" (38 cm)➁
6 = 16.5" (42 cm)
0 = No brakes
FMVSS121 Brake Certification
O = With certification
1 = With certification and ABS
provisions or equipment
Blank = Without certification
Sequential number
specifying unique
model/axle information,
such as camshaft length,
spider model, lining
material, track, etc.
Beam Type
T = Tubular
Beam Capacity➀
lbs
kg
N = 22,500
(10,206)
P = 22,500/
(10,206/
25,000/
11,340/
30,000
13,608)
Q = 25,000/
(11,340/
30,000
(13,608)
R = 22,500/
(10,206/
25,000
11,340)
B = 22,500/
(10,206/
25,000
11,340)
T N
-4 6 7 O Q 2020
Modification
1 = Single wheel
2 = Intermodal
3 = Bolted on brakes
4 = Manual bearing
adjustment
6 = Positive bearing
adjustment
8 = 0.625" nominal
wall axles
9 = 0.75" nominal wall
axles
Brake Width
1 = 10" (25 cm)
6 = 6" (15 cm)➂
7 = 7" or 7.5" (18-19 cm)➃
8 = 8" or 8.625" (22 cm)
9 = 8" (20 cm)
0 = No brakes
➀
➁
➂
➃
Axle Components
P
= Cam
Q
= Cam-Quick
Change
QH = Q with hub
installed
QW = Q with wheel
installed
L
= Q Plus™
cam brake
LH = Q Plus™ with
hub installed
LW = Q Plus™ with
wheel installed
RDA = Stopmaster ®
wedge
D
= Air disc
DH = Air disc with
hub installed
DW = Air disc with
wheel installed
Crank or drop axle beam capacity is 20,000 lbs. (9072 kg).
Disregard rating indicated by second letter of model number.
Denotes either brake drum or brake rotor diameter.
Denotes either brake shoe width or disc brake pad size
(60 square inches)
Denotes either 7" on 16.5" diameter brakes or 7.5" on 12.25"
diameter brakes
4002699a
Figure 10.8
168
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 169 Thursday, August 24, 2006 12:29 PM
11 Transfer Cases
Hazard Alert Messages
Table CG: Publications
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
Model
Maintenance Manual
MTC-4208, -4210 and -4213
Transfer Cases
Maintenance Manual MM-0146
T-2119 Series Transfer Cases
Maintenance Manual
MM-01125
Three-Shaft Design Transfer
Cases
Maintenance Manual 3
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
T-223 Series “Clover Leaf”
Four-Shaft Design Transfer
Cases
Maintenance Manual 3A
T-215 Series Transfer Cases
Maintenance Manual 3B
T-228 Series Transfer Cases
Maintenance Manual 3C
Technical Publications
T-2111 Series Transfer Cases
Maintenance Manual 3D
T-2120RS Two-Shaft,
Single-Speed Transfer Cases
Maintenance Manual 3E
TG-2213 Two-Shaft,
Two-Speed Transfer Cases
Maintenance Manual 3G
Operating Meritor’s
TG-2213RD Transfer Case
Operator Manual TP-98143
11 Transfer Cases
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
How to Obtain Additional Maintenance and
Service Information
Refer to the publications in Table CG. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
Description
Meritor offers a variety of transfer cases constructed to meet a wide range of output shaft requirements. Design features include 4x4 or 6x6
capability, selected gear ratios, declutch, proportional differential, auxiliary drive, parking brake, and two-, three- or four-shaft designs.
Figure 11.1.
Figure 11.1
4000185a
Figure 11.1
Meritor Maintenance Manual 1 (Revised 08-06)
169
mm1.fm.book Page 170 Thursday, August 24, 2006 12:29 PM
11 Transfer Cases
Model Nomenclature
Figure 11.2
Figure 11.3
Number
of Speeds
Transfer Case
Housing
Material
Specification
Number
Low Ratio
M - TC - 4 - 2 - 13 - G - S - 100 - 100 - 205
M = Meritor
Number
of Shafts
Nominal Input
Torque Rating
in High Range
(by 1,000 lb-ft)
Optional Features
Not Included as
Standard Equipment
(Up to Three
Characters)
High Ratio
4001531a
Figure 11.2
Figure 11.4
Transfer Case
Number
of Speeds
1 = Single Speed
2 = Two Speed
Housing
Material
G= Grey Iron
D = Ductile Iron
A = Aluminum
Specification
Number
Low Ratio
M - TC - x - x - xx - x - xxx - 123 - xxxx- xxxx
M = Meritor
Number of Shafts
1 = Single Speed Design
2 = Two Speed Design
3 = Three-Shaft Design
4 = Four-Shaft Design
Nominal Input
Torque Rating
in High Range
(by 1,000 lb-ft)
Optional Features
Not Included as
Standard Equipment
(Up to Three Characters)
C = Oil Cooler Ready
D = Declutch/PTO
F = Differential
L = Lubrication Pump
S = Speed Sensor
B = Brake
High Ratio
4001531b
Figure 11.3
170
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11 Transfer Cases
Lubricant Temperatures
Meritor MTC-4208, MTC-4209 and
MTC-4210 Series Transfer Cases
CAUTION
Meritor MTC-4208, MTC-4209 and MTC-4210 Series transfer
cases may operate with an oil temperature above 300° F
(148° C). However, if the oil temperature reaches 350° F
(177° C), stop the vehicle immediately. Check for the cause of
overheating to prevent damage to components.
Meritor MTC-4208, MTC-4209 and MTC-4210 Series transfer
cases may operate with an oil temperature above 300° F (148° C).
However, if the oil temperature reaches 350° F (177° C), stop the
vehicle immediately and check for the cause of overheating. Oil
temperatures at this range should only occur in linehaul or utility
applications that operate under high speed for long periods of time.
Refer to Maintenance Manual MM-0146, MTC-4208, -4210 and
-4213 Series Transfer Cases.
Other Meritor Transfer Cases
CAUTION
Most Meritor transfer cases can operate above 190° F (88° C)
without damage. However, if the oil temperature reaches
250° F (121° C) for non-synthetic oil or 275° F (135° C) for
synthetic oil, stop the vehicle immediately and check for the
cause of overheating. The maximum continuous running oil
temperature should not exceed 225° F (107° C) for
non-synthetic oil or 250° F (121° C) for synthetic oil. Damage to
components can result.
Do Not Install API GL-5 Oils
CAUTION
Meritor does not approve petroleum-based and multiviscosity
oil. Do not install API GL-5 oils, which contain
extreme-pressure (EP) additives. These additives can form
sludge at normal operating temperatures. Damage to
components can result. Use only SAE Grade 50W synthetic oil
in the transfer case.
Do not install API GL-5 oils in a transfer case. This specification
contains extreme pressure (EP) additives that can form sludge at
normal operating temperatures and damage transfer case
components.
Inspection
Magnets and Magnetic Drain Plugs
Most Meritor transfer cases are equipped with magnetic drain plugs
with a minimum pick-up capacity of 20 ounces (0.57 kg) of low
carbon steel. Replace the magnetic drain plug each time you
change the oil. Use the correct part. If you use a pipe plug instead of
a drain plug, the pipe plug will leak.
You can reuse a drain plug you removed if it has a minimum pick-up
capacity of 20 ounces (0.57 kg) of low carbon steel after you clean
it.
Many Meritor transfer cases and axles have a tapped hole in the
housing for the installation of an oil temperature indicator, which
helps to prevent damage to components that can occur if the oil
temperature is too high.
A high oil temperature lowers oil viscosity levels, which can result in
reduced oil-film thickness between metal parts. If you operate
equipment with this condition over extended periods of time,
damage to components can result.
Meritor Maintenance Manual 1 (Revised 08-06)
171
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11 Transfer Cases
Breather
CAUTION
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving.
2.
Clean the area around the fill plug. Remove the fill plug from
the transfer case. Figure 11.4. The oil level must be even with
the bottom of the fill plug hole.
Cover the breather when steam cleaning the housing. If the
breather is not covered, water can enter the housing and
contaminate the oil.
앫 If oil flows from the hole when you loosen the plug: The
oil level is high. Drain the oil to the bottom of the fill hole.
The breather releases pressure that builds up inside the transfer
case during vehicle operation.
앫 If the oil level is below the bottom of the fill plug hole
or stand pipe: Add the specified oil into the transfer case
until the oil is even with the bottom of the fill hole.
Seals
CAUTION
Always use the correct tools and procedures when you replace
a seal. A seal that is not correctly installed can leak. Damage
to components can result.
Seals keep lubricant in and dirt out of a component. When they are
worn or damaged, seals leak and produce low lubricant levels which
may damage components. Always replace unitized seals after yokes
have been removed.
3.
Install and tighten the fill plug to 35-50 lb-ft (47-68 N폷m). @
4.
Test drive the vehicle for at least one mile (1.6 km). Allow the
oil to settle for five minutes and recheck the fluid level. Top off
the oil level by adding oil to the fill opening. Reinstall and
tighten the fill plug to 35-50 lb-ft (47-68 N폷m). @
Figure 11.5
T-2111 SHOWN
(TYPICAL)
TOP
SHAFT
Check and Adjust the Oil Level
CAUTION
Only use new lubricant when you change or adjust the oil in
the transfer case. Do not reuse lubricant, which can contain
metallic particles and other contaminants. Damage to
components can result.
FILL
PLUG OR CAP
FILL
STAND PIPE
Figure 11.4
Meritor does not approve petroleum-based and multiviscosity
oil. Do not install API GL-5 oils, which contain
extreme-pressure (EP) additives. These additives can form
sludge at normal operating temperatures. Damage to
components can result. Use only SAE Grade 50W synthetic oil
in the transfer case.
Do not operate the transfer case if the oil level is below the
bottom of the fill hole, which may be an indication that the
transfer case is leaking. Damage to components can result. If
the transfer case is leaking, repair the leak. Adjust the oil level
before returning the transfer case to service.
When servicing the transfer case, add the specified lubricant
until the oil level is even with the fill hole. Do not overfill the
transfer case, which can cause the transfer case to overheat.
Damage to components can result.
172
Meritor Maintenance Manual 1 (Revised 08-06)
DRAIN PLUG
1003335a
mm1.fm.book Page 173 Thursday, August 24, 2006 12:29 PM
11 Transfer Cases
Drain and Replace the Oil
Intervals
Transfer Case Oil
Operation
Frequency
Inspect for oil leaks
Daily
Check oil level
1,000 miles (1609 km), 100 hours
or every month, whichever occurs
first
Check oil level
Before and after extended time
high speed road trips
Initial oil change
2,500 miles (4000 km) or
125 hours, whichever occurs first
Synthetic oil change
Every 25,000 miles (40 000 km),
1,250 hours or every 12 months,
whichever occurs first
CAUTION
Only use new lubricant when changing or adjusting the oil in
the transfer case. Do not reuse lubricants which can contain
metallic particles and other contaminants. Damage to
components can result.
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Place a large container under the
transfer case.
2.
Remove the magnetic drain plug from the bottom of the
transfer case. Drain and discard the oil correctly. Clean the
plug. Figure 11.4.
3.
Install and tighten the drain plug to 35-50 lb-ft (47-69 N폷m).
Clean the area around the fill plug. Remove the fill plug from
the transfer case. @
4.
Add the specified oil into the transfer case until the oil level is
even with the bottom of the fill plug hole. Install and tighten the
fill plug to 35-50 lb-ft (47-68 N폷m). @
5.
Test drive the vehicle for 1/4 mile (0.4 km). Allow the oil to
settle for five minutes and recheck the fluid level. Top off the oil
level by adding oil to the fill opening. Reinstall and tighten the
fill plug to 35-50 lb-ft (47-68 N폷m). @
Meritor Maintenance Manual 1 (Revised 08-06)
173
mm1.fm.book Page 174 Thursday, August 24, 2006 12:29 PM
11 Transfer Cases
Specifications
Table CH: Transfer Case Oil Specifications*
Meritor
Oil Description
Specification
A.P.I.
Specification
Military
Specification
SAE Grade
Outside Temperature
Petroleum GL-1 Oil with Rust and
Oxidation Inhibitor1
—
A.P.I. GL-1
—
90W 80W
Above 10° F (–12° C)
Above –15° F (–26° C)
Heavy-Duty Engine Oil1
—
A.P.I.-CD, CE, SF
or SG2
—
50W 40W 30W
Above 10° F (–12° C)
Above –12° F (–26° C)
Full-Synthetic Oil3
O81
—
—
50W
Above –40° F (–40° C)
A.P.I. GL-5 (Axle Lube)4
DO NOT USE IN TRANSFER CASES
1
2
3
4
90W GL-1 or 50W motor oil is the same viscosity and commonly used above 10° F (–12° C).
Current designations are acceptable.
Meritor-approved full-synthetic oil for manual Meritor transmissions is also approved for Meritor transfer cases. Use synthetic oil only if the transfer case was
initially filled with synthetic oil.
Do not use multi-viscosity (i.e., 80/90W) GL-5 gear oil, axle lube.
* Do not use multi-viscosity (i.e., 80/90W) GL-5 gear oil, axle lube. Do not mix or switch oil types. Use the same oil that initially filled the transfer case. Do not
use multi-viscosity oils.
Capacities
Table CI: Transfer Case Oil Capacities
Figure 11.6
Transfer Case
Model
Oil Capacity
Approved Oils
Pints1,212
Liters1,2
Petroleum or
50W Synthetic
2.0
0.95
14.0
6.62
T-215
3.0
1.42
T-221
4.0
1.89
T-223
5.0
2.37
T-226
6.5
3.07
T-228
21.0
9.93
T-232
6.2
2.93
T-1138
13.5
6.38
T-2111
3.0
1.42
T-2111-HD
5.0
2.37
T-2111-HT
5.0
2.37
T-2111-PD
10.0
4.73
T-2111-SD
5.0
2.37
T-2120
4.0
1.89
T-2120-RS
6.5
3.10
T-600
6.2
2.93
T-32
T-136
Transfer Case
Model
Approved Oils
Pints1,212
Liters1,2
50W Synthetic
Only
6.5
3.10
7.0
3.30
MTC-4208
9.0
4.30
MTC-4210
9.0
4.30
MTC-4213
9.0
4.30
TG-2213
T-2119
1
174
Meritor Maintenance Manual 1 (Revised 08-06)
Oil Capacity
2
Due to the varied transfer case configurations, these fill quantities are for
reference only.
Oil Cooler equipped vehicles will use additional oil to compensate for the
cooler and cooler lines.
Refer to bulletin TP-90114, Transmission Lubricant Specifications,
for a list of approved distributors of synthetic oil. To obtain this
publication, refer to the Service Notes page on the front inside cover
of this manual.
mm1.fm.book Page 175 Thursday, August 24, 2006 12:29 PM
11 Transfer Cases
Troubleshooting
Figure 11.7
Clean transfer
case and operate
vehicle.
Inspect transfer case
housing damage and
joint seal leak.
Remove transfer case
from vehicle and
disassemble. Inspect
parts for damage and
replace as needed.
Reassemble transfer
case.
Yes
Damaged
or joint
leak?
Inspect breather
for clog or oil
blowing out.
No
1. Replace the breather.
2. Determine if the breather
is mounted in the correct
location. Call ArvinMeritor’s
Customer Service Center at
800-535-5560 for additional
information.
No
Yes
Breather
clogged?
No
Does oil
blow-out from
the breather?
Yes
Inspect seals
for leaks.
Continue to
next page.
1. Check the transfer case
oil level.
2. Check the transfer case
for air leaks.
Fill the transfer case
with the correct type
and amount of oil.
Road test the
vehicle, then check
for leaks. Return
vehicle to service.
4001525b
Figure 11.5
Meritor Maintenance Manual 1 (Revised 08-06)
175
mm1.fm.book Page 176 Thursday, August 24, 2006 12:29 PM
11 Transfer Cases
Figure 11.8
Continued from
previous page.
Yes
Check the oil level
in the transfer case.
Oil level
too high?
Yes
Seal
leaking?
No
Check oil level, adjust
if necessary, then return
the vehicle to service.
Too much oil or the incorrect
type of oil can cause the
transfer case to overheat,
which may cause seal damage.
No
1. Check the shaft for
excessive movement.
Repair as necessary.
2. Determine if the transfer
case requires an oil
cooler. Call ArvinMeritor’s
Customer Service Center
at 800-535-5560 for
additional information.
Remove
leaking seal.
Check the yoke journal for
burrs, rough edges or
wear grooves. Rub down
any burrs or rough spots. If
a wear groove is present,
replace the yoke.
Install a new seal using
the correct seal driver.
NOTE: An incorrect
installation can cause a
seal leak.
Check the transfer case
for leaks.
Fill the transfer
case with the
correct type and
amount of oil.
Road test the
vehicle, then check
for leaks.
Return vehicle
to service.
4001526b
Figure 11.6
176
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 177 Thursday, August 24, 2006 12:29 PM
11 Transfer Cases
Figure 11.9
EXCESSIVE NOISE AND VIBRATION
DIAGNOSTICS
Determine all driveline angles.
Angles should not exceed
five degrees and the difference
between any of the angles should
not be greater than 1-1/2 degrees.
Check all drivelines
for adequate
balancing.
Replace or
rebalance
driveline.
No
No
Excessive driveline angles
are the leading cause of
drivetrain vibration and
noise. Consult the vehicle
manufacturer.
Yes
Are angles
excessive?
Check U-joints for
excessive wear and
damaged rollers.
Balanced?
Yes
Replace worn
bearings or damaged
components.
Check transfer case
mounting fasteners for
correct torque. Refer to
vehicle manufacturer’s
specifications.
Yes
Wear or
damage?
No
Check for loose or broken
case-to-vehicle mounting
brackets and fasteners.
Replace broken
brackets and/or
tighten all
fasteners to
specified torque.
Road test the
vehicle to
determine if
noise/vibration
is still present.
Yes
Loose
fasteners or
broken
bracket?
Problem
corrected?
No
No
Check all declutch and all
transfer case shafts for
excessive wear. Repair as
necessary.
Yes
Return the
vehicle to service.
4001527a
Figure 11.7
Meritor Maintenance Manual 1 (Revised 08-06)
177
mm1.fm.book Page 178 Thursday, August 24, 2006 12:29 PM
11 Transfer Cases
PTO DOES NOT ENGAGE/DISENGAGE
DIAGNOSTICS
Check air connection to
PTO shift port.
Check indicator light,
and engagement and
disengagement sensors
for correct operation.
No
Light or
sensor
faulty?
Problem
fixed?
Yes
Return the
vehicle to service.
Yes
Return the
vehicle to service.
Replace faulty
indicator light or
sensor, then try to
shift PTO.
Yes
No
Check the available air
pressure. The transfer
case requires at least
60 psi (4.14 bar) at all
times to operate correctly.
No
Air
pressure 65 psi
(4.48 bar) or
more?
No
Problem
fixed?
Correct system air
pressure. Refer to the
vehicle manufacturer’s
instructions.
Return the
vehicle to service.
Yes
Air
system
contaminated?
Yes
Check the piston cylinder on the
PTO. Clean the air supply system.
Refer to vehicle manufacturer’s
instructions. Check that the PTO
engages correctly.
Return the
vehicle to service.
No
Remove the PTO from the transfer case.
Disassemble the PTO and inspect the
bearings, shift collar, shift fork declutch
bore and return spring for damage. Repair
all damaged components.
Verify that the PTO engages and
disengages correctly.
Check the PTO for leaks.
Reassemble and install the PTO on the
transfer case. Road test the vehicle to
confirm the problem is corrected.
Return the vehicle to service.
4001528b
Figure 11.8
178
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 179 Thursday, August 24, 2006 12:29 PM
11 Transfer Cases
Figure 11.10
FRONT AXLE DECLUTCH DOES NOT
ENGAGE/DISENGAGE DIAGNOSTICS
Turn wheels left and right several
times, then try to shift declutch.
Check indicator light,
and engagement and
disengagement sensors
for correct operation.
Light or
sensor
faulty?
No
Problem
fixed?
Yes
Return the
vehicle to service.
Yes
Return the
vehicle to service.
Replace faulty
indicator light or
sensor, then try to
shift declutch.
Yes
No
Check the available air
pressure. The transfer
case requires at least
60 psi (4.14 bar) at all
times to operate correctly.
No
Air
pressure 65 psi
(4.48 bar) or
more?
No
Problem
fixed?
Correct system air
pressure. Refer to the
vehicle manufacturer’s
instructions.
Return the
vehicle to service.
Yes
Air
system
contaminated?
Yes
Check the piston cylinder on the
declutch. Clean the air supply
system. Refer to vehicle
manufacturer’s instructions.
Check that the transfer case
shifts correctly.
Return the
vehicle to service.
No
Remove the transfer case from the vehicle.
Follow disassembly procedures. Inspect
front axle drive gear, shaft, shift collar,
collar engagement teeth on gear, shift
fork, shift fork bore, piston, O-ring and
return spring for damage. Repair all
damaged components.
Reassemble the transfer case. Verify that the transfer
case shifts correctly.
Check the PTO for leaks.
Reinstall the transfer case onto the
vehicle. Road test the vehicle to
confirm the problem is corrected.
Return the vehicle to service.
4001529b
Figure 11.9
Meritor Maintenance Manual 1 (Revised 08-06)
179
mm1.fm.book Page 180 Thursday, August 24, 2006 12:29 PM
11 Transfer Cases
TWO-SPEED TRANSFER CASE HIGH/LOW GEAR SHIFTING DIAGNOSTICS
Turn wheels left and right several times,
then try to shift into high or low gear.
Return the
vehicle to service.
Yes
Yes
Shift transmission to
neutral. Shift transfer
case to neutral. Shift
transmission into first
gear, press lightly on
accelerator.
(PTO models only)
Vehicle
stationary
Problem
fixed?
No
No
Check the available air pressure. The transfer case requires
at least 60 psi (4.14 bar) at all times to operate correctly.
Air
pressure 65 psi
(4.48 bar) or
more?
Correct system
air pressure.
Refer to the
vehicle
manufacturer’s
instructions.
No
Return the
vehicle to
service.
Yes
Yes
Air blowing
out the
breather.
No
Air
system
contaminated?
Yes
No
Remove the transfer
case from the vehicle.
Disassemble and
replace housing
O-ring and piston
O-rings. Reassemble
and check that
transfer case shifts
correctly.
Remove the transfer case from the vehicle.
Remove the shift cylinder and pistons. Inspect
O-rings, pistons, snap rings and shift bore.
Repair any damaged components. Reassemble
and check that transfer case shifts correctly.
Problem
fixed?
Check the piston
cylinder. If dirty,
disassemble shifter
components for
cleaning. Clean the
air supply system.
Refer to vehicle
manufacturer’s
instructions. Check
that the transfer
case shifts correctly.
Yes
Return the
vehicle to
service.
Reinstall transfer
case in vehicle and
return vehicle to service.
No
Problem
fixed?
Yes
Reinstall transfer
case in vehicle and
return vehicle to service.
Disassemble transfer case and inspect shift shaft, shift fork,
shift collar and shift bore. Repair any damaged components.
Reassemble and check that the transfer case shifts correctly.
No
Contact ArvinMeritor’s
Customer Service
Center at 800-535-5560.
Contact ArvinMeritor’s
Customer Service
Center at 800-535-5560.
Figure 11.10
180
Meritor Maintenance Manual 1 (Revised 08-06)
No
Problem
fixed?
Yes
Reinstall transfer
case in vehicle and
return vehicle to service.
mm1.fm.book Page 181 Thursday, August 24, 2006 12:29 PM
12 Transmissions
Hazard Alert Messages
12 Transmissions
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Technical Publications
How to Obtain Additional Maintenance and
Service Information
Refer to the publications in Table CK. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
Table CK: Publications
Model
Manual
ZF-FreedomLine Transmissions
Maintenance and Diagnostics
Manual MM-0150
ZF-FreedomLine Transmission
Wiring Diagram and Fault Code
Diagnostics
Publication TP-01110
SureShift™ Transmission
Maintenance and Diagnostics
Manual MM-9970
SureShift™ Transmission
Wiring Diagram and Fault Code
Diagnostics
Publication TP-98114
SureShift™ Transmission
Operator Manual
Publication TP-99146
Platform “G” 9- and 10-Speed
Transmissions
Maintenance Manual
MM-99106
9-, 10- and 13-Speed
Transmissions
Maintenance Manual 26A
9- and 10-Speed
Transmissions Operator Manual
Publication TP-8989
13-Speed Manual Transmission
Operator Manual
Publication TP-90192
Air Shift Systems/9-Speed
Manual Transmissions
Maintenance Manual 26B
Model
Manual
9- and 10-Speed
Transmissions Operator Manual
Publication TP-8989
13-Speed Manual Transmission
Operator Manual
Publication TP-90192
Air Shift Systems/9-Speed
Manual Transmissions
Maintenance Manual 26B
Air Shift Systems/13-Speed
Manual Transmissions
Maintenance Manual 26D
Electric Over Air (EOA) Range
Shift System: All Meritor 9- and
10-Speed Transmissions
Maintenance and Diagnostics
Manual MM-99140
Engine Synchro Shift™
(ESS™) Transmission with
Meritor’s Transmission Control
Unit (TCU)
Maintenance and Diagnostics
Manual MM-9850
Engine Syncro Shift™ (ESS™)
Transmission with Detroit Diesel
Corporation’s Electronic Control
Module (ECM)
Maintenance and Diagnostics
Manual MM-96152
Engine Synchro Shift™
(ESS™) Operator Manual
Publication TP-95130
Transmissions
Failure Analysis Manual
TP-0445
Description
Meritor offers both manual and automated transmissions for the
heavy-duty trucking industry. Manual transmissions are available in
9, 10 and 13 speeds. Automated SureShift™ transmissions are
available in 9 and 10 speeds. Fully automated ZF-FreedomLine
transmissions are available in 12 and 16 speeds.
12
Meritor Maintenance Manual 1 (Revised 08-06)
181
mm1.fm.book Page 182 Thursday, August 24, 2006 12:29 PM
12 Transmissions
Manual Transmissions
Figure 12.1
Meritor offers constant mesh manual transmissions in 9, 10 and
13 speeds with a full line of torque ratings from 1,150 to
2,050 lb-ft. Transmissions are available with multiple shift system
options and with Meritor Torq-2 and Shift-n-Cruise™. Torq-2
provides an extra 100 lb-ft or 200 lb-ft of increased torque in the
top-two gears without a significant cost premium. The
Shift-n-Cruise™ option is a shift knob with integrated cruise control
switches. The pause, set and resume switches are also conveniently
located in the knob, eliminating the need for drivers to reach for
dashboard controls.
4002714a
Engine Synchro Shift™ (ESS™)
Transmission Shift System
Meritor’s Engine Synchro Shift™ (ESS™) transmission shift system
monitors the positions of the system switch and shift intent switch,
transmission input and output shaft speeds, and the position of the
shift lever in the shift tower. The system relays this data to the
engine control module (ECM), which sends it to the fuel control
system to increase or decrease engine rpm to match road speed.
The ECM also controls high and low range selection in the auxiliary
case.
SureShift™ Transmission
The SureShift™ option is an electronic shift system that significantly
reduces the effort required to safely and accurately shift a constant
mesh manual transmission. With the SureShift™ interface, gear
shifts are accomplished by simply tapping the joystick on the shift
module. The SureShift™ system allows the driver complete control
over which gear the vehicle is in at any given time. The clutch pedal
is only used for starting and stopping. The SureShift™ system is
available with 9- or 10-speed transmissions.
ZF-FreedomLine Transmission
The ZF-FreedomLine is a two-pedal automated transmission that
eliminates the clutch pedal for shifting, starting and stopping. The
system allows the driver to select automatic mode or manual
operation. A self-adjusting clutch is part of the ZF-FreedomLine
system. This eliminates the need for clutch or linkage adjustments.
The ZF-FreedomLine system is available with 12- or 16-speed
transmissions. Figure 12.1.
182
Meritor Maintenance Manual 1 (Revised 08-06)
Figure 12.1
Identification
An identification plate is installed on the side of the transmission.
Use Figure 12.2, Figure 12.3 and Figure 12.4 to identify the
transmission.
mm1.fm.book Page 183 Thursday, August 24, 2006 12:29 PM
12 Transmissions
Model Nomenclature
Refer to Figure 12.2, Figure 12.3 and Figure 12.4 for an explanation of the model identification number and the identification plate.
Figure 12.2
ZF-FREEDOMLINE
MERITOR TRANSMISSION MODEL NUMBER
VEHICLE
MANUFACTURER
TRANSMISSION
PART NUMBER
TRANSMISSION
SERIAL NUMBER
MANUFACTURING
DATE
MERITOR MODEL NUMBER
Meritor
O = Overdrive
No letter =
Direct Drive
Torque
Rating
(lb-ft)
13 = 1350
14 = 1450
15 = 1550
16 = 1650
Vehicle Manufacturer
Specification
Highest Torque in
Transmission (lb-ft)
13 = 1350
14 = 1450
15 = 1550
16 = 1650
A = Fully Automated
Ratio
A
12 = 12-Speed
16 = 16-Speed
Z = ZF-FreedomLine
4002704c
Figure 12.2
Figure 12.3
MERITOR TRANSMISSION MODEL NUMBER
VEHICLE
MANUFACTURER
TRANSMISSION
PART NUMBER
TRANSMISSION
SERIAL NUMBER
MANUFACTURING
DATE
These plugs indicate
oil pump.
MERITOR MODEL NUMBER
Meritor
O = Overdrive
No letter =
Direct Drive
Torque
Rating
(lb-ft)
11 = 1150
12 = 1250
13 = 1350
14 = 1450
15 = 1550
16 = 1650
Design Platform
Ratio
A
B
C
9 =
10 =
12 =
16 =
9-Speed
10-Speed
12-Speed
16-Speed
A
D
E
M
S
=
=
=
=
=
Vehicle Manufacturer
Specification
Highest Torque in
Transmission (lb-ft)
11 = 1150 15 = 1550
12 = 1250 16 = 1650
13 = 1350 18 = 1850
Fully Automated
14 = 1450
ESS — DDC ECM
ESS — Meritor TCU
Manual
SureShiftTM
12
Progressive torque is an engine feature that requires a Torq-2 transmission. In models not featuring progressive
torque, this number will be the same as the torque rating.
4002704d
Detroit Diesel Corporation
Figure 12.3
Meritor Maintenance Manual 1 (Revised 08-06)
183
mm1.fm.book Page 184 Thursday, August 24, 2006 12:29 PM
12 Transmissions
Figure 12.4
MERITOR TRANSMISSION MODEL NUMBER
VEHICLE
MANUFACTURER
TRANSMISSION
PART NUMBER
TRANSMISSION
SERIAL NUMBER
R
MANUFACTURING
DATE
M
X
Meritor
Type
A = Automated
E = Electric/Air
M = Manual
S = Engine Synchro
ShiftTM
W = Shift by Wire
These plugs indicate
oil pump.
MERITOR MODEL NUMBER
10
145
A
Speed
Progressive
Forward
Speeds
S
002
Vehicle Manufacturer
Specification
Ratio
x 10 =
Nominal
Input
Torque
Shift Pattern
No letter = Direct Drive
Standard H Pattern
X = Overdrive Standard
H Pattern
O = Overdrive 9-speed
Non-Standard Pattern
OR
Overdrive 13-speed
Standard H Pattern
2
Shift Bar Housing Position
F = Forward
S = Standard
Design Level
1 = Serial Numbers
LB93001999
and Below
2 = Serial Numbers
LB93002000
and Above
4002705b
Figure 12.4
Intervals
Every 10,000 Miles (16 000 km) of Vehicle
Operation
Table CL: Manual Transmissions, Engine Synchro Shift™
(ESS™), SureShift™ and ZF-FreedomLine
Check Oil
Level
Approved Petroleum
Lubricant Oil
Change
Approved Synthetic
Oil Change
10,000 miles
(16 000 km)
50,000 miles
(80 000 km)
500,000 miles
(800 000 km)*
* This interval is for linehaul applications.
앫
앫
앫
앫
Check and adjust the oil level in the transmission.
Check the condition of the breather vent.
Check the torque of the fasteners.
Inspect for leaks or damage on the transmission. Service as
necessary.
184
Meritor Maintenance Manual 1 (Revised 08-06)
Every 50,000 Miles (80 000 km) of Vehicle
Operation (Approved Petroleum Base and
Heavy-Duty Engine Oils)
앫 Drain and replace the oil in the transmission with approved
petroleum base and heavy-duty engine oils.
Every 500,000 Miles (400 000 km) of Vehicle
Operation (Approved Full-Synthetic Oils)
앫 Drain and replace the oil in the transmission with approved
full-synthetic oils.
mm1.fm.book Page 185 Thursday, August 24, 2006 12:29 PM
12 Transmissions
Inspection
Recommended
Oil Drain Conditions
NOTE: For a list of synthetic oil suppliers, refer to Transmission
Technical Bulletins, TP-2053. To obtain this publication, refer to the
Service Notes page on the front inside cover of this manual.
Oil coolers are recommended on:
앫 All 9-, 10- and 13-speed transmissions behind an engine rated
at 350-398 hp
앫 Some aerodynamic vehicles which restrict air flow over the
transmission causing excessive transmission operating
temperatures
Manual Transmission Oils
If used transmission oil analyses indicate that any one of these
criteria is not met, drain the used oil and replace it with an oil that is
recommended for manual transmissions.
Table CM: Used-Oil Analyses (ppm = parts per million)
Temperature Indicator
The temperature indicator is optional. The temperature sending unit
is on the bottom right side of the main case. The normal operating
temperature range is less than 225° F (107° C).
Use the temperature indicator gauge to check transmission
operation as described in the following example.
Iron (Fe)
If level is greater than 500 ppm, drain and
replace the oil.
Silicon (Si)
If level is greater than 100 ppm, drain and
replace the oil.
앫 If the temperature suddenly rises to 275° F (135° C) or more:
Check the transmission for the cause of the increase.
Water (H2O)
If level is greater than 0.3%, drain and
replace the oil.
앫 When operating a vehicle on a mountain grade, if the
temperature increases 50-75° F (10-24° C) but returns to the
normal operating temperature: This indicates a normal
operating condition. If the temperature does not return to the
normal range, check the transmission.
Magnets and Magnetic Drain Plugs
All transmissions, except for the ZF-FreedomLine, have magnetic
drain plugs and four magnets in the bottom of the main case. The
ZF-FreedomLine has magnetic drain plugs only. The magnets and
magnetic plugs have a minimum pick-up capacity of 1.5 lbs (0.7 kg)
of low carbon steel.
NOTE: Inspect the magnetic drain plug each time the oil is
changed. Use the correct part. Pipe plugs will leak if used as a drain
plug.
The magnetic drain plug can be reused if, after cleaning, the plug has
a minimum pick-up capacity of 1.5 lbs (0.7 kg) of low carbon steel.
Transmission Oil Coolers
Required
Oil coolers are required on:
앫 All ZF-FreedomLine 12- and 16-speed transmissions
앫 All 9-, 10- and 13-speed transmissions behind an engine rated
at 399 hp or above
앫 All 9-, 10- and 13-speed transmissions with continuous
operating temperatures above 225° F (107° C) or intermittent
operating temperatures reaching 275° F (135° C)
Check and Adjust the Oil Level
WARNING
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
Before Checking the Oil Level
1.
The oil must be at room temperature.
2.
The vehicle must be parked for at least 10 minutes.
Check and Adjust the Oil Level Every 10,000 Miles
(16 000 km)
1.
2.
Park the vehicle on a level surface. Place blocks under the
wheels to prevent the vehicle from moving.
12
Inspect the transmission for oil leaks. If a transmission oil leak
is present, refer to the Troubleshooting section in the
appropriate Transmission Maintenance Manual for procedures.
Meritor Maintenance Manual 1 (Revised 08-06)
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12 Transmissions
NOTE: If foam appears when you remove the fill plug, the oil is too
hot to check. Install the oil plug and allow the oil to cool. If oil flows
from the fill plug hole when you remove the plug, the oil level is too
high. Drain the oil to the correct level.
3.
4.
Clean the area by the fill plug. Remove the fill plug from the
side of the transmission.
Check the transmission oil level. Verify that it is even with the
bottom of the fill plug. If the oil level is below the bottom of the
oil fill plug, add the specified oil. Refer to Figure 12.5 for 9-,
10- and 13-speed transmissions. Refer to Figure 12.6 for
12- and 16-speed ZF-FreedomLine transmissions.
5.
Install the oil fill plug and tighten to 35-50 lb-ft (48-67 N폷m). @
6.
Operate the vehicle for five minutes. Check for transmission oil
leaks and correct operation.
7.
Recheck the oil level.
Inspection
Breather Vent Condition
Verify that the breather vent is not damaged. Remove all dirt and oil
from the screen in the breather vent. On the ZF-FreedomLine, the
breather vent condition can only be checked when the transmission
is removed from the vehicle. Figure 12.7.
Figure 12.5
Oil level must be
even with bottom
of fill plug hole.
Figure 12.7
FILL PLUG
DRAIN PLUG
1003336a
Figure 12.5
1000472a
Figure 12.6
Figure 12.7
Fastener Torque
Check the torque on the following fasteners.
앫 Clutch housing to engine flywheel
앫 Top cover housing to main case
앫 All electrical switches on the top cover housing
앫 Drain and fill plugs
Oil level must be
even with bottom
of fill plug hole.
SIDE OIL FILL PLUG
AND PORT
DRAIN
PLUG
4003606a
Figure 12.6
앫 PTO covers to main case
앫 Auxiliary case to main case
앫 Output bearing retainer to auxiliary case
앫 Piston housing cover to auxiliary case
앫 Auxiliary countershaft cover to auxiliary case
앫 Transmission to frame brackets
앫 Output yoke to output shaft
앫 Shift cover housing to top cover housing
186
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12 Transmissions
Inspecting the Transmission for Leaks and
Damage
4.
Inspect the screen on top of the container for metal particles
and damaged parts.
5.
If the transmission is disassembled or replaced and a
transmission oil cooler is used, remove the cooler.
CAUTION
Repair all leaks to prevent damage to the transmission.
Inspect the following transmission parts for cracks, leaks and
damage. Verify that the leaks are transmission oil. Repair all leaks.
앫 Output yoke and the oil seal in the output bearing retainer on the
auxiliary case, non-ZF-FreedomLine models
6.
Remove the oil from the oil cooler and the oil lines. Follow
EPA guidelines to recycle used oil.
B.
Install the oil cooler and the oil lines. Tighten the fittings to
the vehicle manufacturer’s specifications.
Install the drain plug and tighten to 35-50 lb-ft (48-67 N폷m).
@
앫 PTO covers on the main case
앫 Auxiliary case to main case, non-ZF-FreedomLine models
A.
7.
Clean the air by the fill plug. Remove the fill plug from the side
of the transmission.
앫 Main case and the clutch housing, non-ZF-FreedomLine models
앫 Clutch housing to flywheel housing
앫 Auxiliary countershaft covers, non-ZF-FreedomLine models
앫 Slave valve to the main case, non-ZF-FreedomLine models
앫 Shift lever and tower assembly to the top cover,
non-ZF-FreedomLine models
CAUTION
Only use the specified oil. Do not use multi-viscosity engine
oils or Extreme Pressure (EP) GL-5 gear oils. Damage to
components can result. The use of unapproved oils will void
Meritor’s warranty.
8.
Add the specified transmission oil through the fill plug hole.
Add the oil until the oil level is even with the bottom of the fill
plug hole.
9.
Install and tighten the fill plug to 35-50 lb-ft (48-67 N폷m). @
앫 Top cover to the main case, non-ZF-FreedomLine models
앫 Fill and drain plugs
앫 Output bearing retainer to the auxiliary case
앫 Input bearing retainer to the main case
10. Operate the vehicle for five minutes. Check for oil leaks and
correct operation.
앫 Speedometer bore or electronic speed pick-up in the output
bearing retainer
11. Recheck the oil level.
앫 Middle housing to rear housing on ZF-FreedomLine models
Adjustment
Drain and Replace the Oil
Linkage for the Remote Control Assembly
Transmission Oil
NOTE: Drain the oil when the transmission is hot.
1.
Park the vehicle on a level surface. Place blocks under the
wheels to prevent the vehicle from moving.
2.
Place a large container under the transmission. Place a screen
on top of the container.
3.
Remove the drain plugs from the bottom of the transmission.
Drain the oil. Follow U.S. Environmental Protection Agency
(EPA) guidelines to recycle used oil.
Cab-Over-Engine (COE) vehicles use a remote control assembly on
top of the transmission. The linkage connects the inner shift lever to
a shift lever in the cab of the vehicle.
The linkage must be adjusted for correct operation. See the vehicle
manufacturer’s procedure.
12
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12 Transmissions
Lubrication
Figure 12.8
Do not allow grease to enter
the release bearing
inner bushing.
Remote Control Assembly
RELEASE FORK
TIPS AND
RELEASE BEARING
Apply grease to the fittings on the linkage at the interval specified by
the vehicle manufacturer. Use the grease specified by the
manufacturer.
INPUT SHAFT
SPLINE AND
FRICTION PLATE
ZF-FreedomLine Clutch Fork
Lubricate the parts with Castrol Olista Longtime 3 EP lubricant,
Meritor part number 2297-E-8507.
Do not allow grease to enter the inner bushing of the release
bearing.
RELEASE
FORK AT THE
RELEASE
SHAFT
Where to Lubricate
PUSH
ROD
앫 Do not allow grease to enter the release bearing inner bushing.
앫 The release fork tips and release bearing, where the fork tips
contact the bearing. Figure 12.8.
BALL
CUP
4005392a
Figure 12.8
앫 The input shaft spline and friction plate area, when installing a
new transmission.
앫 The release fork, where it pivots on the release shaft.
앫 The ball cup and push rod, where the push rod contacts the ball
cup.
Lubrication Intervals and Specifications
Approved Oil
The following oils have been approved for use in all 9-, 10- and 13-speed manual, SureShift™ and ESS transmissions. The oil change interval
shown is for linehaul applications. All other applications must use oil analysis to determine oil change intervals.
Table CN: 9-, 10- and 13-Speed Transmissions
Oil Description1
Heavy-Duty Engine Oil
Petroleum GL-1 Oil
with Rust and
Oxidation Inhibitor
Full-Synthetic Oil
1
2
Meritor
Specification
—
—
O-81
A.P.I.
Specification
A.P.I. -CD, -CE,
-SG, -SH or SJ 2
A.P.I. - GL-1
—
Military
Specification
Approval
MIL-L-2104 E
or F 2
—
—
SAE
Grade
50
Outside Temperature
Above 10° F (–12° C)
40
Above 10° F (–12° C)
30
90
Above –15° F (–26° C)
Above 10° F (–12° C)
80
Above –15° F (–26° C)
50
Above –40° F (–40° C)
Do not use multi-viscosity or EP (Extreme Pressure) GL-5 gear oils. DO NOT MIX OILS IN THE TRANSMISSION.
Current designations are acceptable.
188
Meritor Maintenance Manual 1 (Revised 08-06)
Change Interval
50,000 miles
(80 000 km)
50,000 miles
(80 000 km)
500,000 miles
(800 000 km)
mm1.fm.book Page 189 Thursday, August 24, 2006 12:29 PM
12 Transmissions
The following oils have been approved for use in all 12- and 16-speed ZF-FreedomLine transmissions. The oil change interval shown is for
linehaul applications. All other applications must use oil analysis to determine oil change intervals.
Table CO: 12- and 16-Speed ZF-FreedomLine Transmissions
Description/
Specification
API Spec
Military Spec
Outside Temperature
Change Interval
Mobiltrans SHC 50
Full-Synthetic Oil
—
—
Above –60° F (–51° C)
500,000 miles
(800 000 km)
Cognis Emgard (#2924)
50W Full-Synthetic Oil
—
—
Above –60° F (–51° C)
500,000 miles
(800 000 km)
Oil Analysis to Determine Oil Change Frequency
Oil Leaks
The oil in the transmission must also be changed if the oil has been
analyzed and contamination has occurred. Refer to Table CM for
recommended guidelines.
Check the transmission for transmission oil leaks. If you find oil on
or under the transmission, verify that the leak is transmission oil and
not engine oil, coolant or other lubricants. Note that under normal
conditions, the area around the oil seal, yoke and rear bearing
retainer is moist. This moist condition is not a transmission leak or
an oil seal leak.
Table CP: Transmission Oil Capacities
Capacity
Model
Pints
Liters
9- and 10-speed manual, SureShift™
and ESS™ transmissions
20.5
9.7
12-speed ZF-FreedomLine
transmission
23.25
13-speed manual transmission
22.0
10.41
16-speed ZF-FreedomLine
transmission
25.0
11.83
11.0
Troubleshooting
On Manual Transmissions
When checking a problem with the manual transmission, the first
thing to do is to verify the service condition. Talk to the driver, the
mechanic or the service manager. If possible, take the vehicle for a
road test.
There are three types of problems.
앫 Leaks
앫 Noise and/or vibration
앫 Operating conditions
On New Transmissions
The following conditions can be found on new transmissions and are
not considered oil leaks.
앫 Lubricants applied to the yoke during assembly can make the
seal area appear moist or “leaking.”
앫 All output seals are pre-lubed with grease that melts at low
temperatures. When the grease melts, it comes out of the seals,
and the seals only appear to be “leaking.”
Vibration
When checking a noise or a vibration, find out when the problem
occurs.
앫 When the transmission is in NEUTRAL or in gear
앫 During upshifts or downshifts
앫 In all gears or specific gears
앫 In the HI range or the LO range
앫 In the DIR range or the OD range (13-speed transmission only)
앫 During coast or acceleration
12
앫 With the vehicle loaded or unloaded
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12 Transmissions
Noise
Also, find out what the transmission does during the problem
If a noise is the problem, find out the sound of the noise.
앫 Does not stay in the selected gear
앫 Growling, humming or grinding
앫 Does not stay in the selected range
앫 Hissing, thumping or bumping
앫 Does not select all gears
앫 Rattles
앫 Does not select all ranges
앫 Squealing
앫 Overheats
앫 Whining
앫 Does not operate
Operation Problems
Troubleshooting Leaks
When the transmission is not operating correctly, find out when the
problem occurs.
Before troubleshooting a leak condition, verify the following:
1.
Clean the outside of the transmission to remove all dirt.
2.
Operate the vehicle to verify that the leak is coming from the
transmission.
앫 In the HI range or the LO range
3.
Verify that the fluid is transmission oil.
앫 In the DIR range or the OD range (13-speed transmission only)
4.
The transmission housings are not cracked or broken.
앫 In NEUTRAL or in gear
앫 During upshifts or downshifts
Table CQ: Troubleshooting Leaks
Condition
Cause
Repair
Leaks — In-Vehicle Repair
Missing fasteners
Replace the missing fasteners. Tighten to the specified
torque.
Loose fasteners
Tighten to the specified torque.
High oil level
Drain to the specified level. Refer to Overheating in
Operating Conditions.
Unspecified oil in transmission
Drain the oil. Install the specified oil.
Clogged or dirty breather vent
Clean the breather vent.
Damaged yoke
Replace the yoke.1
Damaged output shaft seal
Replace the output shaft seal.1
Worn or damaged sealing tape on
electronic speed sensor
Install new sealing tape onto the electronic speed
sensor.
Damaged gaskets or sealing material
Replace the gaskets or sealing material.
Cracked or broken housing
Replace the housing.
Oil leaking from breather vent.2
Replace the O-ring in piston housing.
Leaks — Remove and
Disassemble Transmission
1
2
If the transmission continues to leak and the output shaft seal and the yoke have been replaced, remove and replace the output shaft assembly.
Place the transmission in the LO range and operate the vehicle. If air leaks from the breather vent, the O-ring in the housing of the range cylinder is
damaged.
190
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12 Transmissions
Troubleshooting Vibrations
Before troubleshooting a leak condition, verify the following:
1.
The engine idle speed is within the specified range.
2.
The engine is operating correctly.
3.
The U-joints, yokes and driveshaft are in good condition. Check
the driveline angles. Correct as necessary.
4.
The U-joints, yokes and driveshafts are correctly aligned and/or
balanced. Correct as necessary.
5.
Check the air bag height. Correct as necessary.
Table CR: Troubleshooting Vibrations
Condition
Cause
Repair
Vibration — In-Vehicle Repair
Fasteners do not remain tight
Tighten the fasteners. If the fasteners do not remain
tight, replace the fasteners or housing.
Vibration — Remove and
Disassemble Transmission
Damaged bearings
Replace the bearings.
Broken or loose synchronizer pins*
Replace the synchronizer.
* If the transmission does not shift correctly into the selected range, broken or loose synchronizer pins are the result of the vibration condition.
12
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12 Transmissions
Troubleshooting Noises
For all noise conditions, check the following before disassembling the transmission:
1.
Check that the oil level is even with the bottom of the fill plug hole.
2.
Verify that the correct oil is used.
3.
Verify that the driveline angles of the transmission are correct.
4.
Verify that the transmission is correctly installed.
5.
Remove the drain plug. Check for any metal shavings, gasket material or any other material in the oil.
In some noise conditions, there are additional repairs to perform. These repairs will be explained in the following charts. See the following
charts to troubleshoot the clutch.
Table CS: Troubleshooting Noises
Condition
Cause
Repair
Growling, Humming or
Grinding 1
Worn or damaged gears
Replace the gears.
Worn bearings (humming only)
Replace the bearings.
End play out-of-specifications
Check and adjust the end play.
Damaged bearings (hissing only)
Replace the bearings.
Damaged gear teeth (thumping or
bumping only)
Replace the gears.
Engine idle speed not within specifications
Adjust the idle speed to the specified RPM.
Engine does not operate on all cylinders.
Adjust or repair the engine.
Clutch intermediate or center plate binding
in housing 3
Repair or replace the intermediate or center plate.
Other systems
Verify that the transmission is the source of the rattle
condition.
Incorrect shim installation on the PTO unit
Install the correct shims on the PTO unit.
Rattles — Remove and
Disassemble Transmission
Damaged washers between mainshaft
gear
Replace the washers between the mainshaft gears.
Squealing or Whining —
In-Vehicle Repair 4
Incorrect shim installation on PTO unit
Install the correct shims onto the PTO unit.
Squealing or Whining —
Remove and Disassemble
Transmission 4
Damaged bearings
Replace the bearings.
End play of countershafts not within
specifications
Adjust the countershaft end play within specifications.
Hissing, Thumping or Bumping
Rattles — In-Vehicle Repair
1
2
3
4
2
Growling and humming are associated with the first stages of the condition. Grinding is associated with the severe stages of the condition.
Hissing is associated with the first stages of the condition. Thumping and bumping are associated with the severe stages of the condition.
If the noise occurs when the clutch is engaged and stops when the clutch is disengaged, the intermediate or center place is the cause of the rattle.
Whining is a medium-pitched noise. Squealing is a high-pitched noise.
192
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12 Transmissions
Troubleshooting Operating Conditions
Table CT: Troubleshooting Operating Conditions
Condition
Transmission Slips Out of the
Selected Range — In-Vehicle
Repair
Transmission Slips Out of the
Selected Range — Remove
and Disassemble
Transmission
Transmission is Slow to Shift
or Unable to Shift into the
Selected Range — In-Vehicle
Repair
Transmission is Slow to Shift
or Unable to Shift into the
Selected Range — Remove
and Disassemble
Transmission
Transmission Slips Out of the
Selected Gear — In-Vehicle
Repair
Cause
Loose air lines and fittings
Obstructions in air lines
Check operation of filter/regulator assembly.
Damaged O-ring on piston in range shift
cylinder 1
Loose or missing nut that fastens piston to shift
shaft in range shift cylinder 2
Worn teeth in sliding clutch
Bent or worn shift fork
Worn collar on range shift fork
Loose or leaking air lines and fittings
Obstructions in the air lines
Filter/regulator assembly does not operate
correctly
Spool binding in slave valve
Leakage at slave valve 3
Damaged piston and/or O-rings in piston
housing 4
Worn or damaged neutral interlock pin
Damaged shift knob/selector valve
Damaged exhaust disc in slave valve
Damaged output shaft
Broken or missing synchronizer springs or pins
Damaged synchronizer
Bent or broken shift shaft in range cylinder
Bent or broken shift fork in range cylinder
Dirt between splines and gear
Missing HI/LO fork pin and nut
Incorrect clutch use
Linkage binding or does not move freely
Clutch out-of-adjustment
Remove shift linkage out-of-adjustment
Loose or damaged engine and/or cab mounts
Incorrect driveline angles
Weak or broken detent spring in top cover
assembly
Repair
Tighten the air lines and fittings.
Change the routing or replace the air lines.
Replace the filter/regulator assembly if pressure at
the delivery port is not within 60-65 psi.
Replace the O-ring on the piston.
Tighten or replace the nut.
Replace the sliding clutch.
Replace the shift fork.
Replace the collar on the range shift fork.
Tighten or replace the air lines or fittings.
Change the routing or replace the air lines.
Replace the filter/regulator assembly if pressure at
the delivery port is not 60-65 psi.
Replace the slave valve.
Replace the slave valve.
Replace the O-rings and/or piston in the piston
housing.
Replace the pin.
Replace the shaft knob/selector valve.
Replace the disc in the slave valve.
Replace the output shaft.
Replace the synchronizer springs or synchronizer.
Replace the synchronizer.
Replace the shift shaft.
Replace the shift fork.
Drain the oil. Flush the inside of the housing. Fill to
the specified level with new fluid.
Replace the HI/LO fork pin and nut.
Verify that the driver uses the clutch correctly.
Lubricate, repair or replace the linkage.
Adjust the clutch. Verify that the clutch engages and
releases correctly.
Adjust the remote shaft linkage.
Tighten the fasteners of loose mounts to the
specified torque. Replace the damaged mounts.
Adjust the driveline angles.
Replace the detent spring in the top cover
assembly.
Meritor Maintenance Manual 1 (Revised 08-06)
193
12
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12 Transmissions
Table CT: Troubleshooting Operating Conditions
Condition
Cause
Transmission Slips Out of the
Worn pads on shift fork
Selected Gear — Remove and
Worn teeth in sliding clutch
Disassemble Transmission
Worn fork slot on sliding clutch
Broken key on mainshaft
Twisted mainshaft
Transmission Is Hard to Shift
Incorrect vehicle operation
or Unable to Shift Into the
Clutch out-of-adjustment
Selected Gear — In-Vehicle
Repair
Remote shift linkage binding or unable to move
Transmission Is Hard to Shift
or Unable to Shift Into the
Selected Gear — Remove and
Disassemble Transmission
Transmission Grinds or Initial
Engagement — In-Vehicle
Repair
Loose and/or damaged cab and/or engine
mounts
Detent spring too strong or broken
Bent shift shaft in top cover assembly
Burr on shift shaft in top cover assembly
Cracked top cover assembly
Twisted mainshaft
Broken key on mainshaft
Broken or bent shift fork on sliding clutch
Driver does not operate vehicle correctly.
Clutch out-of-adjustment
Worn, damaged or missing clutch brake
Shift Lever Locks or Sticks in
Gear — In-Vehicle Repair
Shift Lever Locks or Sticks In
Gear — Remove and
Disassemble Transmission
194
Clutch and/or remote shift housing linkage
binding or unable to move
Worn bushings in side of clutch housing
Remote shift linkage out-of-adjustment
Clutch linkage needs adjustment
Linkage binding or unable to move
Loose or damaged cab and/or engine mounts
Damaged balls or rails in top cover assembly
Bent shift fork in top cover
Damaged shift shaft in top cover
Damaged mainshaft
Meritor Maintenance Manual 1 (Revised 08-06)
Repair
Replace the shift fork.
Replace the sliding clutch.
Replace the sliding clutch.
Replace the key and/or mainshaft.
Replace the mainshaft.
Verify that the driver operates the vehicle correctly.
Adjust the clutch. Verify that the clutch engages and
releases correctly.
Lubricate, repair or replace the remote shift linkage.
Tighten the fasteners of loose mounts to the
specified torque. Replace the damaged mounts.
Replace the detent spring.
Replace the shift shaft.
Replace the shift shaft.
Replace the top cover assembly.
Replace the mainshaft.
Replace the key and/or mainshaft.
Replace the fork.
Verify that the driver operates the vehicle correctly.
Adjust the clutch. Verify that the clutch engages and
releases correctly.
Replace the clutch brake. Verify that the clutch
engages and releases correctly.
Lubricate, repair or replace the linkage.
Replace the bushings in the clutch housing.
Adjust the remote shift linkage.
Adjust the clutch linkage.
Lubricate, repair or replace the linkage.
Tighten the fasteners of loose mounts to the
specified torque. Replace the damaged mounts.
Replace the balls or rails.
Replace the shift fork.
Replace the shift shaft.
Replace the mainshaft.
mm1.fm.book Page 195 Thursday, August 24, 2006 12:29 PM
12 Transmissions
Table CT: Troubleshooting Operating Conditions
Condition
Cause
Transmission Overheats —
Incorrect oil level
In Vehicle5, 6
Incorrect oil
Damaged temperature gauge7
Transmission Does Not
Missing or damaged interlock ball in top cover
Operate — Remove and
Free running gears are locked
Disassemble Transmission
Mismatched gear sets
Timing marks on gears not aligned
Broken shafts
1
2
3
4
5
6
7
Repair
Fill to the specified level.
Drain the oil. Use the specified oil.
Replace the temperature gauge.
Replace the interlock ball in the top cover.
Replace the gears.
Install the correct gear sets.
Align the timing marks on the gears.
Replace the shafts.
To check leakage at the range cylinder, first place the selector valve in the LO range. Disconnect the air line to the HI range port on the piston housing.
Operate the vehicle to charge the air system. If air leaks are heard, the O-ring or the piston must be replaced.
When the nut is loose or missing at the end of the shift shaft, the transmission will shift into the HI range but not into the LO range.
To check leakage at the slave valve, first place the selector valve in the LO range. Disconnect the air lines on the slave valve that goes to the HI range port of
the piston housing. Operate the vehicle to charge the air system. If air is heard leaking inside the slave valve, the valve is the cause of the leak.
To check for leaks at the piston housing, disconnect the air lines at the piston housing. Apply air pressure to each port, one port at a time. If air leaks past the
piston, the O-ring and/or the piston must be replaced. If the piston does not move, the shift shaft or the shift assembly is damaged.
If a noise is present along with the overheating condition, refer to the “Troubleshooting Noise” chart to identify and service the noise.
If the oil is at the specified level and the specified oil is used, but the transmission overheats and the oil smells burnt, the transmission must be disassembled
and inspected.
If the oil does not have a burnt smell and the temperature gauge indicates overheating, remove and replace the gauge.
12
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13 Wheel Bearings and Wheel Ends
Hazard Alert Messages
13 Wheel Bearings and Wheel Ends
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle only supported by
jacks. Jacks can slip or fall over. Serious personal injury and
damage to components can result.
Technical Publications
How to Obtain Additional Maintenance and
Service Information
Refer to the publications in Table CU. To obtain these publications,
refer to the Service Notes page on the front inside cover of this
manual.
Conventional Wheel Ends
Description
Conventional wheel ends have the hub, seal, lubricant and bearings
installed onto the axle spindle as separate components.
Figure 13.1. The bearings and seals require periodic inspections
and lubrication to maintain performance.
Trailer axles with conventional wheel ends can be identified by the
following features.
앫 The TN/TQ Series axles use the most common wheel bearings in
the trailer industry.
앫 The TR Series axles use wheel bearings compatible with drive
axles.
앫 The TP Series axles use bearings compatible with Freuhauf
axles.
Figure 13.1
OUTER
BEARING CUP
INNER
LUBRICANT
BEARING CUP
INNER
BEARING CONE
Table CU: Publications
Model
Manual
Front Non-Drive Steer Axles
Maintenance Manual 2
MX Series Medium-Duty Front
Drive Steer Axles
Maintenance Manual
MM-0170
Heavy-Duty Front Drive Steer
Axles
Maintenance Manual 12
Trailer Axles
Maintenance Manual 14
196
Meritor Maintenance Manual 1 (Revised 08-06)
OUTER
BEARING CONE
Figure 13.1
HUB
OIL
SEAL AXLE
SPINDLE
1003333a
mm1.fm.book Page 197 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
Model Nomenclature
Refer to Figure 13.2 and Figure 13.3 for an explanation of axle model numbers.
Figure 13.2
KPI
(inches)
13 =
16 =
21 =
22 =
24 =
33 =
43 =
44 =
51 =
Drop
(inches)
68.0
68.0
69.0
69.0
69.0
71.0
71.5
71.5
72.0
3.74
3.60
3.30
3.50
5.00
3.74
3.74
5.00
3.30
KPI
(inches)
53 =
62 =
63 =
75 =
85 =
86 =
92 =
94 =
72.0
65.24
65.25
60.0
67.5
67.5
68.5
68.5
Drop
(inches)
3.74
3.74
3.74
2.50
2.50
3.60
3.50
5.00
Major Design Variation
A = Conventional Knuckle
B = Integral Tie Rod Arm
C = Integral Tie Rod Arm and
Torque Plate
D = Integral Tie Rod Arm, Spider
and 65 mm Unitized Hub
F = Conventional Knuckle,
58 mm Unitized Spindle
M F S - XX - 0 0 0 X - N X XXX
Manufacturing
Location
N
S
E
A
=
=
=
=
N.A.
S.A.
Europe
Australia/Asia
Axle Spec. Number
M = Meritor
F = Front
S = Non-Drive Steer Axle
GAWR Pounds or Tonnes
Ref: Target Market
Beam, King Pin, Bushing Variation
1 = Forged I-Beam, Straight King Pins —
Easy Steer™ Bushings
2 = Forged I-Beam, Tapered King Pins —
Needle Bearings
3 = Forged I-Beam, Alloy Material, India
4 = Forged I-Beam, Straight King Pins —
Bronze Bushings
Brake Type
B = Reaction Beam
Disc Brake
C = Air Disc Brake
D = Wedge Brake (Dual
Air Chambers)
E = Wedge Brake (Dual
Hydraulic Cylinders)
F = Wedge Brake (Single
Hydraulic Cylinder)
G = DuraPark® Hydraulic
Drum
H = Quadraulic Disc
K = DiscPlus™ Air Disc
Q PlusTM Cam Brake
None
“P” Series Cam Brake
“Q” Series Cam Brake
Cast PlusTM Brake
Wedge Brake (Single
Air Chamber)
T = “T” Series Cam Brake
W = “W” Series Cam
Brake
Z = Non-Meritor Brake
L
N
P
Q
R
S
=
=
=
=
=
=
1003426d
Figure 13.2
13
Meritor Maintenance Manual 1 (Revised 08-06)
197
mm1.fm.book Page 198 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
Figure 13.3
HSG Wall
0
1
2
3
4
5
6
7
8
9
GAWR
xx = GAWR (000) Pounds or Tonnes
(dependent on mfg. location)
Axle Model Type
S=
X=
D=
N=
P=
R=
T=
Z=
C=
H=
Single Rear (Solo)
Front Drive Steer
Fwd Rear w/IAD
Fwd Rear less IAD
Fwd Rear w/Pump
Rear Rear
Tandem Drive
Tridem Drive
Coach
High Entry
Relative Gearing
Size or Series
0
1
2
3
4
5
6
7
8
=
=
=
=
=
=
=
=
=
No Gearing
292/347
337/387
TBD
381/432
415/432
432/457
457
460/498
=
=
=
=
=
=
=
=
=
=
Cast
TBD
0.31 in.
0.37/0.39 in.
0.43 in.
0.50/0.51 in.
0.56 in.
TBD
0.63 in.
TBD
(8 mm)
(9.5/10.0 mm)
(11 mm)
(12.7/13.0 mm)
(14.3 mm)
(16 mm)
Carrier Variation
A=
D=
M=
N=
R=
Aluminum
Ductile
Ductile Rear, Amboid
No Carrier
Ductile Front Drive Axle
Carrier, Right Hand
T = Ductile Telma
Ratio 1
Ratio 2
M X - xx - 1 2 0 x N - x - N 1 2 3 - xxxx - xxxx
M = Meritor
Carrier Type
0
1
2
3
4
5
6
7
9
=
=
=
=
=
=
=
=
=
No Carrier
Single Speed
Two Speed
Helical Double Reduction
Salisbury
Planetary Double Reduction
Hub Reduction
Portal
Single Speed With
Torque Output
Limited Engine
MFG Location
N=
S=
E=
A=
North America
South America
Europe
Australia/Asia/Africa
Wheel End/Brake Attachment/Differential
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
Conventional Spindle/Conventional Brake/Standard Differential
Conventional Spindle/Conventional Brake/DCDL
Conventional Spindle/Conventional Brake/NoSPIN®
Conventional Spindle/Conventional Brake/Other Differential
Unitized Spindle/Conventional Brake/Standard Differential
Unitized Spindle/Conventional Brake/DCDL
Unitized Spindle/Conventional Brake/NoSPIN®
Unitized Spindle/Conventional Brake/Other Differential
Conventional Spindle/Integral Brake/Standard Differential
Conventional Spindle/Integral Brake/DCDL
Conventional Spindle/Integral Brake/NoSPIN®
Conventional Spindle/Integral Brake/Other Differential
Unitized Spindle/Integral Brake/Standard Differential
Unitized Spindle/Integral Brake/DCDL
Unitized Spindle/Integral Brake/NoSPIN®
Unitized Spindle/Integral Brake/Other Differential
Bolt on Conventional Spindle/Conventional Brake/No Differential
Figure 13.3
198
Meritor Maintenance Manual 1 (Revised 08-06)
Specification Number
Includes: TRACK,
PARKING BRAKE, TELMA,
OTHER
Brake Type
B
C
D
E
F
G
H
K
L
N
P
Q
R
S
T
W
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
“B” Frame Brake
Air Disc Brake
Wedge Brake, Dual Air Chambers
Wedge Brake, Dual Hydraulic Cylinders
Wedge Brake, Single Hydraulic Cylinder
DuraPark Hydraulic Drum
Qualdraulic Disc
Disc PlusTM Air Disc
Q Plus Cam Brake
None
P Series Cam Brake
Q Series Cam Brake
Cast PlusTM Brake
Wedge Brake, Single Air Chamber
T Series Cam Brake
W Series Cam Brake
4002706a
mm1.fm.book Page 199 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
Oil-Lubricated Wheel Bearings
Trailer Axle Wheel-End Oil Change
Inspection and Maintenance
CAUTION
If you cannot observe the oil level because the sightglass is stained,
remove the fill plug, check the oil level with your finger and follow
the procedures for Step 3 below. Replace the stained sightglass as
soon as possible.
1.
Park the vehicle on a level surface. Place blocks under the
wheels to prevent the vehicle from moving.
2.
Check the oil level on the cap.
3.
If the oil level is more than 1/4-inch (6 mm) below the specified
level on the cap, remove the fill plug.
4.
Add the specified oil to the specified level. Figure 13.4.
It is important to not overfill the wheel-end cavity with
lubricant. The wheel-end oil level should never exceed the
middle of the hubcap. Also, verify that any excess oil is wiped
away since it can contaminate the brake linings and cause
poor performance. Damage to components can result.
Inspect the wheel-end oil level at least every 1,000 miles
(1600 km). To check, verify that the vehicle is on level ground. Clean
the hubcap window and observe the oil level. Add lubricant if the oil
level is down more than 0.25-inch (6.3 mm) from the fill line.
Figure 13.5.
Figure 13.5
Figure 13.4
TYPICAL OIL-LUBRICATED WHEEL BEARINGS
LUBE
Below 0.25" (6.3 mm) — add oil.
1003338a
4002701a
Figure 13.5
Figure 13.4
5.
Install the fill plug.
Drive Axle Hubs Without Fill Holes
1.
Add the specified amount of lubricant through the carrier or
housing bowl oil fill hole.
2.
Tilt the axle to the right and to the left to let the oil flow into the
hub cavities. Keep the axle tilted for one minute in each
position.
3.
With the axle in the level position, add the specified oil so that
the level is even with the bottom of the fill plug hole.
4.
Install and tighten the fill plug.
Fill the wheel end with an approved gear oil to the hubcap fill line.
Note that the oil must be given sufficient time to settle prior to the
final check of the oil level. This is especially important in cold
conditions. Figure 13.6.
Figure 13.6
Shading indicates
correct amount
of oil.
4002700a
Figure 13.6
13
Meritor Maintenance Manual 1 (Revised 08-06)
199
mm1.fm.book Page 200 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
Lubrication Intervals and Specifications
Table CV: Wheel-End Oil Change Intervals
Operation
On-Highway
Off-Highway
Check Oil Level
1,000 miles (1600 km)
1,000 miles (1600 km)
Petroleum Oil
Change
Whichever comes first. Seals replaced. Brakes relined.
100,000 miles (160 000 km). Once a year.
Whichever comes first. Seals replaced. Brakes relined.
Once a year.
Synthetic Oil Change
Whichever comes first. Seals replaced. Brakes relined.
100,000 miles (160 000 km). Once a year.
Whichever comes first. Seals replaced. Brakes relined.
Once a year.
Table CW: Approved Lubricants
Outside Temperature
Meritor
Specifications
°F
°C
Military/SAE Specifications
Oil Description
Min.
Max.
Min.
Max.
MIL-PRF-2105-E and
SAE J2360
GL-5, SAE 85W/140
–10
None
–12
None
GL-5, SAE 80W/90
–15
None
–26
None
O-76-E Gear Oil
GL-5, SAE 75W/90
–40
None
–40
None
O-76-J Gear Oil
GL-5, SAE 75
–40
35
–40
2
O-76-M
Full-Synthetic Oil
GL-5, SAE 75W/140
–40
None
–40
None
O-76-N
Full-Synthetic Oil
GL-5, SAE 75W/90
–40
None
–40
None
O-76-A Gear Oil
O-76-D Gear Oil
Heavy-Duty
Engine Oil
MIL-L-2104 E or F
A.P.I. -CD, -CE, -SG, -SH or
-SJ SAE 40 or 501
–10
None
–12
None
Heavy-Duty
Engine Oil
MIL-L-210 E or F
A.P.I. -CD, -CE, -SG, -SH or
-SJ SAE 30 12
–15
None
–26
None
1
2
Current designations are acceptable. Multi-grade engine oils are acceptable if the SAE rating ends in 40 or 50.
Current designations are acceptable. Multi-grade engine oils are acceptable if the SAE rating ends in 30.
200
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 201 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
Table CX: Conventional Trailer Axle Wheel-End Oil Change Intervals and Specifications
Outside Temperature
Check Oil
Level
1,000 miles
(1600 km)
Oil Change*
Specification Oil
Approval
Description
°F
Min.
Max.
Min.
Max.
MIL-PRF-210
5-E and SAE
J2360
GL-5 SAE
85W/140
–10
None
–12
None
GL-5 SAE
80W/90
–15
None
–26
None
O-76-E Gear Oil
GL-5 SAE
75W/90
–40
None
–40
None
O-76-J Gear Oil
GL-5 SAE
75W
–40
35
–40
2
O-76-L Gear Oil
GL-5 SAE
75W/140
–40
None
–40
None
O-76-M
Full-Synthetic Gear
Oil
GL-5 SAE
75W/140
–40
None
–40
None
O-76-N
Full-Synthetic Gear
Oil
GL-5 SAE
75W/90
–40
None
–40
None
O-81 Full-Synthetic
Oil
SAE 50
–40
None
–40
None
Meritor
Specification
General Service: Change oil if
O-76-A Gear Oil
the wheel end is disturbed during
wheel or hub removal or if the oil O-76-D Gear Oil
is contaminated.
Standard-Duty Service: For
100,000 miles (160 000 km) or
more a year, change the oil every
100,000 miles (160 000 km).
For less than 100,000 miles
(160 000 km) a year, change the
oil once a year.
Heavy-Duty Service: For
60,000 miles (96 000 km) or
more a year, change oil every
30,000 miles (48 000 km).
For less than 60,000 miles
(96 000 km) a year, change the
oil every 6 months.
°C
* The recommended oil change interval is based on operating conditions, speeds and loads. Limited service applications may allow the recommended interval
to be increased. Severe service applications may require the recommended interval to be reduced. For more information, contact ArvinMeritor’s Customer
Service Center at 800-535-5560.
Grease-Lubricated Wheel Bearings
6.
Inspection and Maintenance
1.
2.
Park the vehicle on a level surface. Place blocks under the
wheels to prevent the vehicle from moving.
Raise the vehicle so that the wheels are off the ground.
Support the vehicle with safety stands.
Use a pressure packer to force the specified grease from the
large end of the cones into the cavities between the rollers and
cage. Pack the hub between the bearing cups with grease to
the level of the smallest diameter of the cups.
앫 If a pressure packer is not available: Grease the
bearings by hand.
7.
Install the inner and outer bearing cones into the cups in the
hubs. The bearing cups must be pressed tight against the
shoulder in the hubs.
3.
Remove the tire and wheel assembly. Remove and dissemble
the hub.
4.
Use the correct cleaning solvent to remove the old grease from
all parts. Discard the seals. Inspect the wheel bearings for
wear or damage. Replace worn or damaged bearings.
8.
Install new wheel seals into the hubs.
9.
Install the hub and the wheel and tire assembly. Install the
outer wheel bearing cone into the hub. Install the adjusting nut.
Before installing the wheel bearings, lubricate the bearing
journals on the spindle with the grease that is used for the
bearings.
10. Adjust the wheel bearings.
5.
13
Meritor Maintenance Manual 1 (Revised 08-06)
201
mm1.fm.book Page 202 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
Trailer Axle Wheel-End Grease Change
Figure 13.7
WARNING
Do not use gasoline to clean parts. Gasoline can explode or
burn and cause serious personal injury.
CAUTION
It is important to not overfill the wheel-end cavity with
lubricant. Do not extend the grease level indicated below. Also,
verify that the excess grease is wiped away since it can
contaminate the brake linings and cause poor brake
performance. Damage to components can result.
NOTE: Instructions for installing components such as seals,
bearings and hubs are located in Maintenance Manual 14, Trailer
Axles. To obtain this publication, refer to the Service Notes page on
the front inside cover of this manual.
1.
2.
To remove grease from a wheel end, use a stiff fiber brush, not
steel, and kerosene or diesel fuel oil, not gasoline. Allow the
clean parts to dry, then wipe with a clean, absorbent cloth.
Note that any solvent residue must be completely wiped dry
since it may either dilute the grease or prevent it from correctly
adhering to the wheel-end components.
Shading
indicates
correct amount
of grease.
4002702a
Figure 13.7
3.
Lubricate a wheel end with approved NLGI 00 grease as
follows.
A.
Pack the bearing cones with grease by forcing the grease
into the cavities between the rollers and the cage from the
large end of the cone. The use of a pressure packer is
recommended; otherwise, pack the bearing by hand.
B.
Apply a light coat of synthetic grease to the spindle
bearing journals. Refer to A in Figure 13.8.
C.
Install the hub onto the spindle without the outer bearing
cone in place.
Lubricate a wheel end with approved NLGI 1 or 2 grease as
follows.
A.
Pack the bearing cones with grease by forcing the grease
into the cavities between the rollers and the cage from the
large end of the cone. The use of a pressure packer is
recommended; otherwise, pack the bearings by hand.
B.
Apply a light coat of grease to the spindle bearing
journals.
D.
Fill the hub cavity with synthetic grease to the outer cup’s
smallest diameter. Refer to B in Figure 13.8.
C.
Pack the area of the hub between the two bearings with
grease up to the smallest diameter of the bearing cups.
Figure 13.7.
E.
D.
Apply a light coat of grease to the interior of the hubcap
and wheel retention hardware to indicate what lubricant is
installed as well as help prevent corrosion of these parts.
At the top of the spindle and as far back as possible,
pump additional synthetic grease until it appears that the
grease will run out. Install the outer bearing cone quickly.
Refer to C in Figure 13.8.
F.
The hub cavity will be filled approximately 1/3 full with
grease, from the four to the eight o’clock positions.
Figure 13.8.
NOTE: Do not install any grease in the hubcap.
G.
202
Meritor Maintenance Manual 1 (Revised 08-06)
Install the wheel retention hardware. Place a dab of
synthetic grease across the face of the outer locknut for
identification.
mm1.fm.book Page 203 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
Figure 13.8
C
A
A
B
Shading indicates
correct amount of grease.
4002703a
Figure 13.8
Lubrication Intervals and Specifications
Table CY: Wheel-End Axle Greasing Intervals and Specifications
Meritor
Specification
Greasing Interval
Grease
Whichever comes first:
Multi-Purpose
Grease
Replacing Seals
Relining Brakes
O-617-A
(preferred) or
O-617-B
(acceptable)
NLGI Grade
1 or 2
Grease
Description
Outside
Temperature
Lithium
12-Hydroxy
Stearate or
Lithium Complex
Refer to the
grease
manufacturer’s
specifications for
the temperature
service limits.
On-Highway: 30,000 miles (48 000 km)
On/Off Highway and Off-Highway: Twice a year
Table CZ: Conventional Trailer Axle Greasing Intervals and Specifications
Greasing Interval*
Grease
Meritor
Specification
NLGI
Grade
Grease
Description
Outside
Temperature
General Service: Grease the bearings if the wheel end is
disturbed during wheel or hub removal or if the grease is
contaminated.
Multi-Purpose
Grease
O-617-A or
O-617-B
1 or 2
Lithium
12-Hydroxy
Stearate or
Lithium
Complex
Trailer Axle
Bearing
O-647
00
Lithium
Complex
Refer to the
grease
manufacturer’s
specifications for
the temperature
service limits.
Standard-Duty Service: For 100,000 miles (160 000 km)
or more a year, grease the bearings every 100,000 miles
(160 000 km). For less than 100,000 miles (160 000 km)
a year, grease the bearings once a year.
Heavy-Duty Service: For 60,000 miles (96 000 km) or
more a year, grease the bearings every 30,000 miles
(48 000 km). For less than 60,000 miles (96 000 km) a
year, grease the bearings every 6 months.
* The recommended greasing interval is based on operating conditions, speeds and loads. Limited service applications may allow the recommended interval to
be increased. Severe service applications may require the recommended interval to be reduced. For more information, contact ArvinMeritor’s Customer
Service Center at 800-535-5560.
Meritor Maintenance Manual 1 (Revised 08-06)
203
13
mm1.fm.book Page 204 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
Important Information
Identification
Meritor automatic slack adjusters (ASAs) should not need to be
manually adjusted in service. ASAs should not have to be adjusted
to correct excessive pushrod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ASA,
brake actuator or other system components.
A Meritor front non-drive steer axle with unitized hubs has “half
moons” embossed on the center of the hubcaps. Figure 13.9. If the
hubcaps are missing, you can use the axle model number to
determine if the axle is equipped with unitized hubs. To identify the
model number, check the identification tag located on the front of
the axle beam.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ASA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
The axle identification tag fastened to the center of the axle beam
shows the model and specification number, and axle assembly date
for Meritor front non-drive steer axles with unitized hubs.
Figure 13.10. Also included on the tag are the customer number,
axle assembly plant and serial number.
Figure 13.9
For Meritor brake adjustment, refer to the brake adjustment tables
in this manual. For non-Meritor brake adjusters, refer to the brake
manufacturer’s service procedures.
HALF MOONS
Long-Life Wheel Ends
Front Non-Drive Steer Axles with Unitized
Hubs
A unitized hub is a sealed assembly with a bearing package that’s
greased for the life of the component. Wheel bearing adjustment,
seal installation and periodic lubrication are not required.
If you disassemble or attempt to repair or lubricate a unitized hub,
you will void Meritor’s warranty.
A unitized hub is not adjustable. You don’t set or adjust wheel
bearing end play.
4001199a
Figure 13.9
Figure 13.10
VIEW OF AXLE BEAM
FACING VEHICLE
You must inspect a hub assembly for the life of the component.
The inspection procedures in this section do not instruct you to
disassemble a unitized hub.
Meritor front non-drive steer axles with unitized hubs use
conventional brakes, automatic slack adjusters, and tire and wheel
assemblies. For service information on Meritor cam brakes and
automatic slack adjusters, refer to the Service Notes page on the
front inside cover of this publication.
Axle spindle retention hardware consists of an inner tabbed lock
washer and inner wheel bearing adjusting nut, and an outer tabbed
lock washer and outer wheel bearing adjusting nut.
MODEL AND
SPECIFICATION NUMBER
MODEL MFS-12-143D-N
CUSTOMER NO 01X21A62
ASSY PLANT & SERIAL NO AVF 9521109
DATE 01327
AXLE ASSEMBLY
DATE
Figure 13.10
204
Meritor Maintenance Manual 1 (Revised 08-06)
CUSTOMER
NUMBER
TAG
EXAMPLE
AXLE ASSEMBLY PLANT
AND SERIAL NUMBER
1000319e
mm1.fm.book Page 205 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
A unitized hub may also be referred to as a truck hub unit, Easy
Steer Plus™ or a unitized hub. However, if a hubcap is embossed
with “half moons,” it’s a unitized hub.
Meritor Axles Equipped with Unitized Hubs
Table DA: Model Numbers
When you apply some silicone gasket materials, a small
amount of acid vapor is present. To prevent serious personal
injury, ensure that the work area is well-ventilated. Read the
manufacturer’s instructions before using a silicone gasket
material, then carefully follow the instructions. If a silicone
gasket material gets into your eyes, follow the manufacturer’s
emergency procedures. Have your eyes checked by a
physician as soon as possible.
MFS-10-143D-N
MFS-12-144D-N
FF-983
MFS-10-144D-N
MFS-13-144D-N
FF-984
MFS-12-122D-N
FF-981
FF-986
Inspection Intervals
MFS-12-143D-N
FF-982
FF-987
Refer to these inspection and maintenance procedures for Meritor
axles equipped with unitized wheel ends on front non-drive steer
axles. You must perform detailed and basic inspections at the
following intervals.
Model Nomenclature
Refer to Figure 13.2 and Figure 13.3 for an explanation of axle
model numbers.
Detailed Inspections
Refer to the procedure in this section.
Inspection Procedure
앫 After the initial 200,000 miles (321 800 km) of operation
WARNING
YOU MUST FOLLOW THE UNITIZED WHEEL-END MAINTENANCE
AND INSPECTION PROCEDURES PROVIDED IN THIS MANUAL
TO PREVENT SERIOUS PERSONAL INJURY AND DAMAGE TO
COMPONENTS.
앫 After every additional 200,000 miles (321 800 km) of operation
thereafter
Basic Inspections
앫 UNITIZED WHEEL ENDS ARE NOT ADJUSTABLE.
앫 DO NOT ATTEMPT TO SET OR ADJUST END PLAY.
After the initial 200,000-mile (321 800 km) detailed inspection,
perform a basic inspection at each scheduled preventive
maintenance interval, not to exceed 50,000-mile (80 467 km)
intervals. Refer to the procedure in this section.
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
If the Vehicle is Equipped with ABS on the Steer Axle
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
®
Take care when you use Loctite adhesive to avoid serious
personal injury. Read the manufacturer’s instructions before
using this product. Follow the instructions carefully to prevent
irritation to the eyes and skin. If Loctite® adhesive material
gets into your eyes, follow the manufacturer’s emergency
procedures. Have your eyes checked by a physician as soon
as possible.
In addition to the scheduled preventive maintenance, if the driver
reports indicate the ABS light has been coming on, and ABS
diagnostics indicate the sensor gap is out-of-adjustment, check for
possible wheel-end looseness as the cause.
Tools Required
Basic Inspection
A jack, wheel blocks and safety stands
Detailed Inspection
A dial indicator and a torque wrench with 700 lb-ft (949 N폷m)
capability
13
Meritor Maintenance Manual 1 (Revised 08-06)
205
mm1.fm.book Page 206 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
Basic Inspection
The unitized wheel end is sealed and greased for life and does not
require lubrication. If you disassemble, or attempt to repair or
lubricate a unitized wheel-end assembly, you will void Meritor’s
warranty. The basic inspection procedures do not instruct you to
disassemble the unitized wheel end.
To Help Determine the Cause of Wheel-End
Assembly Looseness or Movement
1.
Check the wheel-to-hub mounting. Verify that the wheel is
mounted correctly and all wheel-end fasteners and hardware
are tightened to the correct specification.
2.
Apply the service brake to lock the hub and spindle assembly
together.
앫 Unitized wheel ends are not adjustable.
앫 If you detect movement or looseness: The king pin or
king pin bushings should be inspected. Refer to
Maintenance Manual 2, Front Non-Drive Steer Axles. To
obtain this publication, refer to the Service Notes page on
the front inside cover of this manual.
앫 Do not attempt to set or adjust end play.
1.
Park the vehicle on a level surface. Block the rear wheels to
prevent the vehicle from moving.
2.
Raise the vehicle so that the front wheels are off the ground.
Support the vehicle with safety stands. Do not use a jack to
support the vehicle.
NOTE: If a ticking sound is detected during rotation, this does not
indicate a hub problem. It is a normal occurrence.
3.
Visually inspect the unitized wheel end as you rotate the tire
and unitized wheel-end assembly. Verify that it rotates
smoothly and without noise. While rotating the wheel, grasp
the brake chamber to feel for unitized wheel-end hub vibration.
앫 If the tire and unitized wheel-end assembly does not
rotate smoothly, or you hear noise (such as wheel
bearing grind) or feel wheel-end hub vibration during
rotation: Perform a detailed inspection. Refer to the
procedure in this section.
앫 If the wheel end rotates smoothly: Proceed to the next
step.
4.
Grasp the tire and wheel-end assembly at the nine and
three o’clock positions. Check for vertical and horizontal
movement. With your hands, apply approximately 50 lb (23 kg)
of force to the assembly. You should not feel or see any
looseness or movement.
앫 If you feel or see any movement or looseness in the
tire and wheel-end assembly: Perform a detailed
inspection to determine the cause of the movement, such
as worn king pin bushings or pins; wheel-to-hub-mounting
end play; unitized wheel-end hub end play; or a
combination of them all. To determine unitized wheel-end
hub end play, refer to the procedure in this section.
If other front axle components, such as king pin bushings,
require inspection or service, refer to Maintenance Manual 2,
Front Non-Drive Steer Axles. To obtain this publication, refer to
the Service Notes page on the front inside cover of this
manual.
206
Meritor Maintenance Manual 1 (Revised 08-06)
앫 If applying the service brake eliminates movement or
looseness: Proceed to the procedure in this section to
determine the unitized wheel-end hub end play.
Detailed Inspection
The unitized wheel end is sealed and greased for life and does not
require lubrication. If you disassemble, or attempt to repair or
lubricate a unitized wheel-end assembly, you will void Meritor’s
warranty. The detailed inspection procedures provided in this
section do not instruct you to disassemble the unitized wheel end.
앫 Unitized wheel ends are not adjustable.
앫 Do not attempt to set or adjust end play.
1.
Park the vehicle on a level surface. Block the rear wheels to
prevent the vehicle from moving.
2.
Remove the hubcap.
3.
Raise the vehicle so that the front wheels are off the ground.
Support the vehicle with safety stands. Do not use a jack to
support the vehicle.
NOTE: The outboard and inboard seals may purge small amounts
of grease that are visible during inspection. Figure 13.11. This is a
normal occurrence.
4.
Remove the wheel and drum. Attach the magnetic base of a
dial indicator to the end of the spindle. Figure 13.12. Touch the
indicator stem perpendicular against the unitized wheel end’s
mounting face.
mm1.fm.book Page 207 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
Figure 13.11
Figure 13.13
PROTECTIVE
HUBCAP
UNITIZED
WHEEL END
INNER
WHEEL
OUTER
WHEEL BEARING
NUT
BEARING
NUT
GREASE
O-RING
TABBED
WASHER
INNER “D”
WASHER
1000063e
Figure 13.13
NOTE: The inner wheel bearing nut and the outer wheel bearing nut
are identical, but the torque values are different.
7.
Install the tabbed washer and outer wheel bearing nut onto the
spindle. Tighten the outer wheel bearing nut to 200-300 lb-ft
(271-476 N폷m). @
8.
Reattach the dial indicator. Set the dial indicator to ZERO.
Do not rotate the wheel end. Place your hands at the nine and
three o’clock positions.
9.
Push the unitized wheel end straight IN. Note the reading.
Pull the unitized wheel end straight OUT. Note the reading.
4000876c
Figure 13.11
Figure 13.12
DIAL INDICATOR
앫 If the total movement of the dial indicator is greater
than 0.003-inch (0.08 mm), but less than 0.006-inch
(0.15 mm): Record the measurement in a maintenance
log, and perform a basic inspection at the next
regularly-scheduled maintenance interval, or not to exceed
50,000 miles (80 467 km), whichever comes first.
4001329a
Figure 13.12
5.
6.
Set the dial indicator to ZERO. Do not rotate the wheel end.
Place your hands at the nine and three o’clock positions.
Push the unitized wheel end straight IN. Note the reading.
Pull the unitized wheel end straight OUT. Note the reading.
앫 If the total movement of the dial indicator is less than
0.003-inch (0.08 mm): Inspection is complete. No
adjustment is required.
앫 If the total movement of the dial indicator is 0.006-inch
(0.015 mm) or greater: Replace the unitized wheel-end
hub. You must inspect a replacement hub before you install
it. Refer to the procedure in this section.
10. After you’ve taken the measurement, bend the parts of the
tabbed washer that protrude over the flats of the outer wheel
bearing nut and the inner wheel bearing nut. Bend the washer
a minimum of one flat edge to each nut.
앫 If the total movement of the dial indicator is 0.003-inch
(0.08 mm) or greater: Remove the outer bearing nut and
tabbed washer. Tighten the inner wheel bearing nut to
500-700 lb-ft (679-949 N폷m) while rotating the unitized
wheel end a minimum of five rotations. Figure 13.13. @
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13 Wheel Bearings and Wheel Ends
NOTE: If a ticking sound is detected during rotation, this does not
indicate a hub problem. It is a normal occurrence.
3.
11. Verify that the unitized wheel end rotates smoothly and without
noise. While rotating the wheel, grasp the brake chamber to
feel for unitized wheel-end hub vibration.
앫 If the unitized wheel-end assembly does not rotate
smoothly, or you hear noise (such as wheel bearing
grind) or feel wheel-end hub vibration during rotation:
Replace the unitized wheel-end hub. You must inspect a
replacement hub before you install it. Refer to the
procedure in this section.
Examine the exterior of the hub to verify the following.
A.
There is no visible damage to the inboard or outboard
seals and the bearings have not become unseated.
Figure 13.15 and Figure 13.16.
B.
The tone ring teeth are not damaged and there are no
broken or missing teeth on the tone ring. Figure 13.16.
Figure 13.15
앫 If the wheel end rotates smoothly: Inspection is
complete. Reinstall the wheel-end equipment. Return the
vehicle to service.
OUTBOARD
SEAL
Replacement Hub Inspection
1.
2.
Remove the replacement hub from the box and place it on a
clean surface.
Examine the interior of the hub to verify the following.
A.
The inner clip ring has not become dislodged in shipment
and is in correct alignment with the inner and outer
bearings. The gap between the inner and outer bearing
sets and the clip ring must be equal. Figure 13.14.
B.
The gap between the ends of the clip ring must be equal
and not exceed 0.25-inch (6 mm). If necessary, adjust by
hand. Figure 13.14.
C.
The bearing face must be clean with no seal coating, dirt
or dust.
4001197a
Figure 13.15
Figure 13.16
INBOARD
SEAL
TONE
RING
Figure 13.14
A
4001198a
INNER
BEARING
SET
C
Figure 13.16
CLIP
RING
Install the Spindle O-Rings and Hubcaps
B
OUTER
BEARING
SET
A AND B MUST BE EQUAL
C MUST NOT EXCEED 0.25" (6 MM)
Figure 13.14
208
Meritor Maintenance Manual 1 (Revised 08-06)
4001196a
Refer to Maintenance Manual 2, Front Non-Drive Steer Axles, for
procedures to install the spindle O-rings and hubcaps.
mm1.fm.book Page 209 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
Trailer Axles with Long-Life Wheel Ends
The TB and TL Series trailer axles feature a permanently-sealed and
lubricated unitized wheel-end assembly designed to help reduce
wheel-end maintenance.
The unitized wheel end is designed to remain in place on the axle for
a minimum of five years or 500,000 miles (800 000 km).
On a unitized wheel end, you install the hub, seal, lubricant and
bearings onto the axle spindle as an assembly. Figure 13.17.
Figure 13.17
AXLE SPINDLE
UNITIZED HUB ASSEMBLY
1003332a
Figure 13.17
For TB Series unitized wheel-end service procedures, refer to
Maintenance Manual MM-0420, Trailer Axles with Unitized Wheel
Ends. To obtain this publication, refer to the Service Notes page on
the front inside cover of this manual.
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13 Wheel Bearings and Wheel Ends
Model Nomenclature
Refer to Figure 13.18 for an explanation of axle model numbers.
Figure 13.18
CURRENT PRODUCTION MODEL NUMBERS
Design Variation➀
C = Crank
D = Drop
Blank = Straight
Brake Diameter
2 = 12.25" (31 cm)
5 = 15" (38 cm)➁
6 = 16.5" (42 cm)
0 = No brakes
FMVSS121 Brake Certification
O = With certification
1 = With certification and ABS
provisions or equipment
Blank = Without certification
Sequential number
specifying unique
model/axle information,
such as camshaft length,
spider model, lining
material, track, etc.
Beam Type
T = Tubular
Beam Capacity➀
lbs
kg
N = 22,500
(10,206)
P = 22,500/
(10,206/
25,000/
11,340/
30,000
13,608)
Q = 25,000/
(11,340/
30,000
(13,608)
R = 22,500/
(10,206/
25,000
11,340)
B* = 22,500/
(10,206/
25,000
11,340)
L** = 20,000
(9072)
T N
-4 6 7 O Q 2020
Modification
1 = Single wheel
2 = Intermodal
3 = Bolted on brakes
4 = Manual bearing
adjustment
6 = Positive bearing
adjustment
8 = 0.625" nominal
wall axles
9 = 0.75" nominal wall
axles
*B = Unitized Bearing Hub
**L = Packaged Bearing Hub
Brake Width
1 = 10" (25 cm)
6 = 6" (15 cm)➂
7 = 7" or 7.5" (18-19 cm)➃
8 = 8" or 8.625" (22 cm)
9 = 8" (20 cm)
0 = No brakes
➀
➁
➂
➃
Axle Components
P
= Cam
Q
= Cam-Quick
Change
QH = Q with hub
installed
QW = Q with wheel
installed
L
= Q Plus™
cam brake
LH = Q Plus™ with
hub installed
LW = Q Plus™ with
wheel installed
RDA = Stopmaster ®
wedge
= Air disc
= Air disc with
hub installed
DW = Air disc with
wheel installed
D
DH
Crank or drop axle beam capacity is 20,000 lbs. (9072 kg).
Disregard rating indicated by second letter of model number.
Denotes either brake drum or brake rotor diameter.
Denotes either brake shoe width or disc brake pad size
(60 square inches)
Denotes either 7" on 16.5" diameter brakes or 7.5" on 12.25"
diameter brakes
4002699b
Figure 13.18
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13 Wheel Bearings and Wheel Ends
TB Series Trailer Axles with Unitized Hub
Assemblies
Figure 13.19
DIAL
INDICATOR
TB Series trailer axles with unitized hub assemblies can be identified
by the following features.
STEM
앫 The model number designation for the TB Series is prefixed with
TB; for example, TB-4670 or TB-8670.
앫 The axle spindles are shorter with a single journal.
앫 The hubs contain non-serviceable bearings, seals and lubricant.
MAGNETIC
BASE
앫 The hubcaps screw onto the axle spindle and have no provisions
for adding lubricant.
앫 The axle spindle retention hardware features a thicker inner nut
and a bendable tab lock washer.
4001742a
Figure 13.19
2.
앫 Warranty information is stamped on each unitized wheel-end
hubcap.
Push the hub INWARD until the dial indicator does not change.
Set the dial indicator to ZERO. Figure 13.20.
Figure 13.20
Removal of long-life bearings, seals or lubricant from the Meritor
TB Series trailer axle unitized hub assembly will void the warranty.
Refer to publication TP-96175, Servicing Meritor’s TB Series Trailer
Axles with Unitized Hub Assemblies, or call ArvinMeritor’s Customer
Service Center at 800-535-5560 for information.
PUSH
Inspection and Maintenance
NOTE: Do not attempt to rebuild the hub. There are no serviceable
components in the hub assembly.
1.
2.
Inspect the unitized hub for smooth rotation at each brake
reline.
Inspect the unitized hub for smooth rotation and correct end
play every year or 100,000 miles (160 934 km), whichever
comes first.
Smooth Hub Rotation
1.
Rotate the hub in both directions.
2.
If the bearing feels rough or sounds noisy, replace the hub.
Hub End Play
1.
Attach the magnetic base of a dial indicator to the end of the
axle spindle and touch the dial indicator stem against the hub.
Figure 13.19.
4001743a
Figure 13.20
3.
Pull OUTWARD until the dial indicator does not change.
Figure 13.21. The difference between pushing INWARD and
pulling OUTWARD is end play.
앫 If wheel bearing end play is less than 0.003-inch
(0.0762 mm): The adjustment procedure is complete.
No further action is required.
앫 If wheel bearing end play is 0.003-inch (0.0762 mm) or
more: Retighten the wheel bearing adjusting nut and
recheck the end play.
앫 If wheel bearing end play is 0.006-inch (0.1524 mm) or
more: Replace the unitized hub.
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13 Wheel Bearings and Wheel Ends
Figure 13.21
PULL
Small amounts of grease may be visible at the hub’s outer seal.
This is a normal occurrence and does not indicate a seal leak.
However, if a large amount of grease is visible, the seal is leaking.
Replace the hub. Figure 13.24.
Figure 13.24
NORMAL
GREASE
CONDITION
OUTER
SEAL
4001744a
Figure 13.21
Seal Leaks
Check the back of the hub for a seal leak. The hub incorporates a
grease seal. A leak of this seal will appear like that in a conventional
wheel end. Figure 13.22.
4001725a
Figure 13.24
Figure 13.22
TL Series Trailer Axles with Packaged
Bearing Hub Assemblies
The TL Series trailer axles with packaged bearing hub assemblies
can be identified by the following features.
앫 The packaged bearing hub assembly has a metal hubcap
secured by capscrews. “Half moons” are embossed in the center
of the hubcap.
4001745a
Figure 13.22
During hub installation, a small amount of grease will appear at the
spindle back-up collar to hub joint. This is normal and does not
indicate a seal leak. Figure 13.23.
Figure 13.23
TB MODEL
Some grease
may appear
in this area.
HUB
SPINDLE
BACKUP
COLLAR
4001746a
Figure 13.23
212
Meritor Maintenance Manual 1 (Revised 08-06)
앫 The trailer axle identification tag shows TL at the beginning of
the model number.
앫 The axle spindle is a “barrel” design.
앫 Warranty and service information are included on the hubcap.
Inspection Schedule
Check wheel bearing end play whenever a wheel end is off the
ground, during a brake repair, when the hubcap or axle shaft is
removed, when an ABS sensor “out of adjustment” fault occurs,
or every 12 months or 100,000 miles (160 000 km), whichever
comes first.
Inspect the packaged bearing hub assembly for smooth rotation
every 100,000 miles (160 000 km) or 12 months, whichever
comes first.
mm1.fm.book Page 213 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
Inspect the packaged bearing hub assembly for smooth rotation at
each brake reline. Rotate the hub in both directions. If the bearing
feels rough or sounds noisy, replace the hub. If a large amount of
grease is visible at the hub’s outer seal, replace the hub.
Inspect the packaged bearing hub assembly for smooth rotation and
movement if driver reports indicate that the anti-lock braking system
(ABS) warning lamp comes on during operation, and ABS
diagnostics indicate a gap exists between the wheel speed sensor
and tooth wheel (sensor out-of-adjustment).
Inspection Procedure
WARNING
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.
1.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Use a jack to raise the trailer until the
tires are off the ground. Place safety stands under the trailer
frame or axles. Do not use a jack to support the trailer.
2.
Attach an air line to the trailer emergency glad hand
connection.
Inspect the Inner and Outer Grease Seals for Leaks
When the hub assembly is installed, a small amount of grease may
appear at the spindle backup collar-to-hub joint. This is a normal
occurrence and does not indicate that a seal is leaking.
1.
Inspect the hub assembly’s inner grease seal for leakage.
A leaking seal will stain the back of the hub with lubricant,
a condition similar with a conventional hub.
앫 If the seal is leaking: Replace the hub assembly.
2.
Inspect the hub assembly’s outer grease seal for leakage.
A small amount of grease around the perimeter of the seal is
a normal occurrence and doesn’t indicate that the seal is
leaking.
앫 If you find a large amount of grease on the entire
surface of the seal and surrounding hub surfaces:
Replace the hub assembly.
앫 If the brake linings still touch the brake drums:
Use the automatic slack adjuster to manually back-off the
brake shoes.
Check the Hub Assembly for Smooth Rotation and
Noise
You can perform this procedure with or without the tire and wheel
assembly installed.
1.
Rotate the hub assembly and listen for bearing noise. Worn
bearings make a low-pitch grinding sound. If the tire is
installed, the wheel will amplify the noise.
2.
Place your hand on the brake air chamber that services the
wheel end. Feel for any bearing vibration as the hub assembly
rotates. The air chamber will amplify bearing vibration. For
example, if there’s dirt in the hub seal, you may hear a noise
similar to a worn bearing, In this case, rely more on vibration
than noise.
앫 If you feel wheel bearing vibration or hear noise: Check
the wheel bearing end play.
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13 Wheel Bearings and Wheel Ends
Trailer Lubrication Intervals and Specifications
Table DB: Camshaft Bushing and Slack Adjusters Greasing Intervals and Specifications
Greasing Interval*
Grease
Meritor
Specification
NLGI
Grade
Grease
Description
Outside
Temperature
Use the schedule below that
gives the most frequent
lubrication.
Multi-Purpose
Grease
O-617-A or
O-617-B
1 or 2
Lithium 12-Hydroxy
Stearate or Lithium
Complex
Refer to the grease
manufacturer’s
specifications for
the temperature
service limits.
앫 The lubrication schedule of
the fleet.
앫 The lubrication schedule of
the vehicle manufacturer.
앫 A minimum of four times
during the life of the brake
linings.
* Applies to standard-duty on-highway service. Lubricate more frequently for heavy-duty applications. Determine intervals by inspecting the lubricant every
two weeks for a four-month period. Look for hard, contaminated or missing grease. Choose an interval based on the inspection.
TRIAD™ Trailer Axle Wheel-End System
Installing Spindle Nuts on Trailer Axle Models TN,
TQ and TP
Use the following procedure to install spindle nuts on trailer axle
models TN, TQ and TP equipped with TRIAD™ trailer axle wheel
ends.
Removal of the bearings, seals or lubricant from the hub voids
the warranty.
1.
Install the adjusting nut against the hardened washer. Tighten
the nut to 150-200 lb-ft (204-272 N폷m) while rotating the
wheel-end assembly. @
3.
Completely loosen the adjusting nut. Tighten the nut to 25 lb-ft
(34 N폷m) while rotating the wheel-end assembly. @
4.
Install the tabbed washer against the adjusting nut.
5.
Install the retainer nut against the tabbed washer. Tighten the
nut to 25 lb-ft (34 N폷m). @
Align the tab with a flat surface of the retainer nut. If necessary,
turn the nut COUNTERCLOCKWISE to align the closest flat with
the tab.
Install the hardened washer against the outer bearing.
Figure 13.25.
Figure 13.25
SPINDLE
HARDENED
WASHER
RETAINER
NUT
TABBED
WASHER
ADJUSTING
NUT
4005450a
Figure 13.25
214
2.
Meritor Maintenance Manual 1 (Revised 08-06)
6.
Bend the washer tab OUTWARD over the flat surface of the
retainer nut.
7.
Apply 200-275 lb-ft (272-374 N폷m) of torque to rotate the
adjusting nut in a COUNTERCLOCKWISE direction and jam it
against the tabbed washer and retainer nut. @
mm1.fm.book Page 215 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
Wheel-End Equipment Checks
Studs and Nuts
The following warnings are to alert you to stud and nut conditions
and maintenance procedures that can affect your safety and the
integrity of the vehicle and its components.
Carefully read the warnings before you install disc wheels.
WARNING
Replace bent, loose, broken or stripped studs. When you
replace a stripped stud, always replace the stud on each side
of the stripped stud as well. Even if the adjoining studs are not
cracked, they have sustained fatigue damage, which can
cause the wheels to loosen and separate from the vehicle.
Serious personal injury and damage to components can result.
Always replace a serrated stud, bolt, with a new one. Do not
reuse a serrated stud, which will not tighten correctly and can
cause the wheels to loosen, to separate from the vehicle.
Serious personal injury and damage to components can result.
Do not apply paint to mounting surfaces, studs or nuts. Paint
decreases a fastener assembly’s capability to maintain clamp
load, which can cause wheels to loosen and separate from the
vehicle. Serious personal injury and damage to components
can result.
Ensure that you do not damage the stud threads. Damaged
threads will not allow the stud to provide the required clamp
load to support the wheel retention system. The wheels can
loosen and separate from the vehicle. Serious personal injury
and damage to components can result.
Check that stud standout is correct for stud-piloted wheels. If
standout exceeds specifications even though the correct
torque is used, the cap nut can bottom against the hub stud
and loosen both wheels and the brake drum, which will cause
the wheels to separate from the vehicle. If standout is too
short, the cap nut will overload and crack, causing the inner
and dual wheels to separate from the vehicle. Serious personal
injury and damage to components can result.
Install right-hand studs on the right side of the vehicle and
left-hand studs onto the left side of the vehicle. Studs that are
not installed correctly can loosen, which can cause the wheels
to loosen and separate from the vehicle. Serious personal
injury and damage to components can result.
Do not lubricate the studs or nut threads. Lubricants will not
enable you to tighten the fasteners correctly, which causes
excessive clamp load. The studs can break and cause the
wheels to loosen and separate from the vehicle. Serious
personal injury can result.
Do not install 1-1/2-inch hex two-piece flange nuts onto
M22 x 1.5 serrated studs when 33 mm two-piece hex nuts are
used on the CentroMount-8™ system. The wheels can crack,
loosen and separate from the vehicle. Serious personal injury
and damage to components can result.
Install aluminum wheel nuts onto an aluminum disc wheel.
Do not install steel wheel nuts. Steel wheel nuts can damage
an aluminum wheel or cause the dual wheels to loosen and
separate from the vehicle. Serious personal injury and damage
to components can result.
Install steel wheel nuts onto steel wheels. Do not install
aluminum wheel nuts. The extension on an aluminum wheel
nut can bottom against the hub flange or brake drum before
the disc wheel is clamped correctly, which can cause the
wheels to separate from the vehicle. Serious personal injury
and damage to components can result.
Install the nuts with the correct thread size onto the studs.
A nut with an incorrect thread size will not turn freely on the
stud or will fit loosely on the stud. The thread can strip, which
can cause loss of clamp load. The wheels can loosen and
separate from the vehicle. Serious personal injury and damage
to components can result.
Install the correct wheel system components for the
application. Do not mix wheel system components. The wheels
can loosen and separate from the vehicle. Serious personal
injury and damage to components can result.
Add two drops of oil between the nut flange and the hex
portion of the swivel area at each installation if you reinstall
the two-piece flange nuts that have been in service. Without
lubrication, the fasteners may not produce adequate clamp
load, and the wheel(s) can loosen and separate from the
vehicle. Serious personal injury and damage to components
can result.
1.
Check the studs. Repair or replace loose, bent, stripped or
broken studs.
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13 Wheel Bearings and Wheel Ends
2.
Check for correct serrated stud standout.
Figure 13.28
A.
Figure 13.26 shows correct standout.
B.
Figure 13.27 and Figure 13.28 show incorrect standout.
C.
Serrated studs do not usually interchange with those in
various hub part numbers. Check the application. Call
ArvinMeritor’s Customer Service Center at
800-535-5560 for more information.
INCORRECT: STUD
TOO SHORT; INADEQUATE
SUPPORT FOR CAP NUT
Figure 13.26
CORRECT:
STUD STANDOUT
4001690a
Figure 13.28
3.
Check for R and L stamped in the end of the stud.
Figure 13.29. Install right-hand studs onto the right side of the
vehicle, and left-hand studs onto the left side of the vehicle.
Figure 13.29
RIGHT- AND LEFT-HAND
FASTENERS
4001688a
R
Figure 13.26
L
Figure 13.27
4001691a
INCORRECT: STUD TOO LONG;
BOTTOMS IN CAP NUT
Figure 13.29
4001689a
Figure 13.27
216
Meritor Maintenance Manual 1 (Revised 08-06)
4.
Some manufacturers color code studs. Check the
manufacturer’s instructions to verify the color code used.
5.
Install the correct nut into all applications. Do not install rusty,
galled or worn nuts. Ensure that you use the correct nuts in the
following installations.
앫 Install 33 mm hex two-piece flange nuts into ISO 285.75 mm
bolt circle diameter (BC) and ISO 335 mm BC systems.
앫 Install 1-1/2-inch hex two-piece flange nuts into a 275 mm
system with M22 x 1.5 serrated studs. Do not install
1-1/2-inch hex two-piece flange nuts onto M22 x 1.5
serrated studs when 33 mm two-piece hex nuts are used
on the CentroMount-8™ system.
mm1.fm.book Page 217 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
6.
Install aluminum wheel nuts onto aluminum wheels. Do not
install steel wheel nuts. An aluminum wheel nut has an
extension to accommodate the thickness of the aluminum.
Figure 13.30 and Figure 13.31.
Figure 13.32
CORRECT: STEEL WHEEL NUT
ON STEEL WHEEL
Figure 13.30
CORRECT: ALUMINUM WHEEL
NUT ON ALUMINUM WHEEL
4001694a
Figure 13.32
4001692a
Figure 13.33
INCORRECT: ALUMINUM WHEEL NUT
ON STEEL WHEEL
Figure 13.30
Figure 13.31
INCORRECT: STEEL WHEEL NUT
ON ALUMINUM WHEEL
4001695a
Figure 13.33
4001693a
8.
Install nuts with the correct thread size onto the studs.
A correct thread size enables the nut to turn freely on the stud.
An incorrect nut will fit very loosely on the stud thread, which
can cause the thread to strip.
9.
Check the extension of the stud through the nut after you
tighten the nut to the specified torque.
Figure 13.31
7.
Install steel wheel nuts onto steel wheels. Do not install
aluminum wheel nuts. The extension of the aluminum wheel
nut can bottom against the hub flange or brake drum before
the disc is clamped correctly. Figure 13.32 and Figure 13.33.
앫 If less than two threads extend through the nut, or
more than 3/8-inch (9.5 mm) of the stud extends
through the nut: Check all parts to verify that they
are correct for the wheel system you will install on the
vehicle.
13
Meritor Maintenance Manual 1 (Revised 08-06)
217
mm1.fm.book Page 218 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
10. Ensure that the nut and wheel mate correctly. Ensure that you
install the correct components onto the wheel systems.
Figure 13.34 and Figure 13.35.
Figure 13.35
앫 If the wheel has a ball seat bolt hole pattern: The nut
must have a spherical surface that seats in the ball seat.
앫 If the wheel has a cylindrical bolt hole pattern: The nut
must have a flat surface that seats against the wheel.
Figure 13.34
CORRECT: HUB-PILOTED WHEELS ON HUB-PILOTED HUB
CORRECT: BALL SEAT WHEEL ON BALL SEAT HUB
INCORRECT: BALL SEAT WHEELS ON HUB-PILOTED HUB
4001699b
Figure 13.35
INCORRECT: HUB-PILOTED WHEEL ON BALL SEAT HUB
11. Follow the disc wheel manufacturer’s fastener tightening
sequence when you install fasteners to help ensure a higher
and more uniform clamp load. Figure 13.36. Always check
fasteners at the wheel manufacturer’s recommended service
intervals.
4001697b
Figure 13.36
Figure 13.34
1
10
3
6
1
5
4
4
7
3
6
5
4
7
5
9
8
STUD-PILOTED AND HUB-PILOTED
SINGLE AND DUAL WHEELS
Meritor Maintenance Manual 1 (Revised 08-06)
2
6
3
218
8
2
2
Figure 13.36
1
4001686a
mm1.fm.book Page 219 Thursday, August 24, 2006 12:29 PM
13 Wheel Bearings and Wheel Ends
12. Add two drops of oil between the nut flange and the hex portion
of the swivel area at each installation if you reinstall the
two-piece flange nuts that have been in service. Do not oil the
stud or nut threads.
Figure 13.37
M22X1.5
THREAD
HUB
3/4-16
THREAD
13. Retighten all wheel nuts on all systems at 50-100 miles
(80-160 km) to the correct torque specifications.
ROTOR
14. Use the correct installation tools.
15. Ensure that the gross weight does not exceed gross vehicle
weight (GVW). Ensure that the axle loads do not exceed gross
axle weight ratings (GAWR).
Installing Double-Ended Metric Wheel Studs
with 3/4-16 and M22 x 1.5 Threads Onto Hub
and Rotor Assemblies on Axles Equipped
with Meritor Air Disc Brake Model ADB 1560
Important Note: The 390-450 lb-ft (529-610 N폷m) torque
specification provides sufficient clamp load to install a hub-piloted
wheel on one end of the double-ended wheel stud and not exceed
the torque capacity of the 3/4-16 threads on the opposite end.
The wheel stud is a standard design and has been in production
since 1987.
4005394a
Figure 13.37
Vehicles Equipped with ABS
In addition to the scheduled preventive maintenance, if the driver
reports indicate the ABS light has been coming on, and ABS
diagnostics indicate the sensor gap is out-of-adjustment, check for
possible wheel-end looseness as the cause.
Use this specification rather than 450-550 lb-ft (610-746 N폷m),
which is usually specified when installing hub-piloted wheels.
Installation Procedure
ASBESTOS AND NON-ASBESTOS
FIBERS WARNING
Some brake linings contain asbestos fibers, a cancer and lung
disease hazard. Some brake linings contain non-asbestos
fibers, whose long-term effects to health are unknown. You
must use caution when you handle both asbestos and
non-asbestos materials.
WARNING
Tighten the fasteners to the correct torque specifications.
Do not over-tighten or under-tighten fasteners, which can
cause the wheels to separate from the vehicle. Serious
personal injury and damage to components can result.
1.
Tighten the inner 3/4-16 nuts to 100 lb-ft (136 N폷m) to seat
the wheel studs. Figure 13.37. @
2.
Tighten the outer M22 x 1.5 nuts to 390-450 lb-ft
(529-610 N폷m) to install the hub-piloted wheels. @
13
Meritor Maintenance Manual 1 (Revised 08-06)
219
mm1.fm.book Page 220 Thursday, August 24, 2006 12:29 PM
14 Specifications
Lubrication Intervals and Specifications
14 Specifications
Grease Lubricants
Table DC: Grease Lubricants*
Meritor
Specification
O-616
Grease
Brake Grease
O-616-A
Brake Grease
O-617-A or
O-617-B
Multi-Purpose
Grease
O-634-B
Universal Joint
Grease
O-6372
Special
Rust-Preventing
Brake Grease
Low-Temperature
Brake Grease
O-645
O-647
O-661
O-692
1
2
Trailer Axle
Bearing Grease
High-Temperature
Multi-Purpose
Wheel Bearing
Grease
Automatic Slack
Adjuster Grease
Typical Application
Cam Brake Anchor Pins, Mechanical
Brake Anchor Pins
Air Disc Brake Caliper, Automatic
Slack Adjuster, Wedge Brake
Components
Cam Brake Chamber Brackets, Cam
Brake Hold Down Clips, Cross Tube
Ends, Drag Link, Wheel Bearings,
King Pins and Bushings, Knuckle
Bushings, Manual Slack Adjuster,
Steering Arm, Ball Studs, Tie Rod End
Ball Studs, Trailer Axle Wheel
Bearings, Wedge Brake Hold-Down
Clips, Wedge Brake Shoe Contacts at
Anchors
Driveshaft Slip Yokes, Driveshaft
Splines, Driveshaft Universal Joints
NLGI
Grade
2
Grease Description
Clay Base
Outside
Temperature
1
Clay Base
Down to –40° F
(–40° C)
1 or 2
Lithium 12-Hydroxy
Stearate or Lithium
Complex
1
2
1
1-1/2
Lithium 12-Hydroxy
Stearate with
Molybdenum Disulfide
Calcium
1
1
Air Disc Brake Slide Pin, Splines and
Clevis Pins, Cam Brake Camshaft
Splines
Air Disc Brake Caliper, Automatic
Slack Adjuster, Wedge Brake
Components
Trailer Axle Wheel Bearings
2
Synthetic
Down to –65° F
(–54° C)
00
Synthetic
1
Clutch Release Bearing
3
Lithium Complex
1
Automatic Slack Adjuster
1 and 2
Lithium Base
Down to –40° F
(–40° C)
Refer to the manufacturer’s specifications for the temperature service limits.
Do not mix O-637 calcium-base, corrosion-control grease with other greases.
* Grease recommendations are based on commercial products that have given satisfactory results in normal operation. However, there are many proprietary
grease products on the market which will perform satisfactorily and may be preferable because of supply problems, common usage for other truck
components, etc. When such products are recommended by reputable suppliers for the specific lubrication of our components, Meritor has no objections,
provided that these substitute products are equal to or better than Meritor recommendations in lubrication properties, water resistance, corrosion protection,
high and low temperature characteristics, oxidation stability, shear stability, etc. All substitute products are subject to Meritor approval. For more information,
contact an ArvinMeritor service representative.
220
Meritor Maintenance Manual 1 (Revised 08-06)
mm1.fm.book Page 221 Thursday, August 24, 2006 12:29 PM
14 Specifications
Oil Lubricants
Table DD: Oil Lubricants
Outside Temperature
Meritor
Specification Oil
Typical Application
°F
°C
Military/SAE
Specifications
Oil Description Min.
Max. Min.
Max.
O-62
Petroleum Transfer Case
Oil
—
SAE 90
–10
None –12
None
O-63
Petroleum Transfer Case
Oil
—
SAE 140
–40
None –4
None
O-76A
Gear Oil
Front Drive Axle, Front Drive Axle Wheel
Bearings, Non-Drive Axle Wheel
Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
MIL-PRF-2105-E GL-5 SAE
and SAE J2360 85W/140
–10
None –12
None
O-76D
Gear Oil
Front Drive Axle, Front Drive Axle Wheel
Bearings, Non-Drive Axle Wheel
Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
GL-5 SAE
80W/90
–15
None –26
None
O76E
Gear Oil
Front Drive Axle, Front Drive Axle Wheel
Bearings, Non-Drive Axle Wheel
Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
GL-5 SAE
75W/90
–40
None –40
None
O-76J
Gear Oil
Front Drive Axle, Front Drive Axle Wheel
Bearings, Non-Drive Axle Wheel
Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
GL-5 SAE
75W
–40
35
2
O-76L
Gear Oil
Front Drive Axle, Front Drive Axle Wheel
Bearings, Non-Drive Axle Wheel
Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
GL-5 SAE
75W/140
–40
None –40
None
O-76M
Full
Synthetic
Oil
Front Drive Axle, Front Drive Axle Wheel
Bearings, Non-Drive Axle Wheel
Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
GL-5 SAE
75W/140
–40
None –40
None
O-76N
Full
Synthetic
Oil
Front Drive Axle, Front Drive Axle Wheel
Bearings, Non-Drive Axle Wheel
Bearings, Planetary Axle, Rear Drive
Axle, Trailer Axle Wheel Bearings
GL-5 SAE
75W/90
–40
None –40
None
O-81
Full
Synthetic
Oil
Transmission
SAE 50
–40
None –40
None
—
–40
Meritor Maintenance Manual 1 (Revised 08-06)
221
14
mm1.fm.book Page 222 Thursday, August 24, 2006 12:29 PM
14 Specifications
Table DD: Oil Lubricants
Meritor
Specification Oil
Outside Temperature
Typical Application
Military/SAE
Specifications
°C
Oil Description Min.
Max. Min.
Max.
A.P.I. -CD, -CE,
-SG, -SH or
-SJ; SAE 50
–10
None –12
None
—
Heavy
Transmission
Duty
Engine Oil
—
Heavy
Transmission
Duty
Engine Oil
A.P.I. -CD, -CE,
-SG, -SH or
-SJ; SAE 40
–10
None –12
None
—
Heavy
Transmission
Duty
Engine Oil
A.P.I. -CD, -CE,
-SG, -SH or
-SJ; SAE 30
–15
10
–12
—
Petroleum Transmission
Gear
A.P.I.-GL-1;
SAE 90
–10
None –12
None
—
Petroleum Transmission
Gear
A.P.I.-GL-1;
SAE 80
–15
None –26
None
* Current designations are acceptable.
222
Meritor Maintenance Manual 1 (Revised 08-06)
MIL-L-2104 -E
or -F*
°F
–26
mm1.fm.book Page -7 Thursday, August 24, 2006 12:29 PM
Meritor Heavy Vehicle Systems, LLC
2135 West Maple Road
Troy, MI 48084 USA
Copyright 2006
800-535-5560
ArvinMeritor, Inc.
arvinmeritor.com
Printed in USA
Revised 08-06
Maintenance Manual 1 (16579/22882)
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