MAINTENANCE MANUAL - Meritor

MAINTENANCE MANUAL 

Axle Single-Reduction Differential 

MS - 145/147 

MS - 155 

MS - 160 

MS - 165 

MS - 168 

MS - 185 

MS - 186 

RS - 120 

U - 180 

U - 185 

Edition September/11

Index 

1 - Alterations to the Shaft......................................................................................... 03 

2 - Introduction........................................................................................................... 04 

3 - Exploded View...................................................................................................... 05 

4 - Identification......................................................................................................... 07 

5 - Disassembly......................................................................................................... 08 

6 - Preparation for the Assembly............................................................................... 14 

7 - Liquid Lock........................................................................................................... 18 

8 - Chemical Joint...................................................................................................... 20 

9 - Assembly.............................................................................................................. 21 

10 - Adjustments.......................................................................................................... 39 

11 - Main Satellite Box Blocking System..................................................................... 44 

12 - Lubrication............................................................................................................ 58 

13 - Torque Table........................................................................................................ 59 

MAINTENANCE MANUAL

Alterations to the Shaft 

In order to maintain the maintenance manual 

updated, for each alteration made to the shaft, a 

Technical Instruction will be issued with the data 

and implications arising from this alteration. 

In the footer of each page of this manual there 

is an area designated to noting down the number 

of each Technical Instruction which involves 

possible alterations occurring on that page 

as shown in the example below. 

Safety 

It is of paramount importance to use safety 

equipment when maintaining the shaft. 

• When using a hammer or executing any operating 

involving impact, wear safety goggles. 

• When handling parts which are hot or have 

sharp edges, wear suitable gloves. 


3

Introduction 

The Meritor differentials of simple speed are drive 

units which the following features: 

• Hypoid Crown and Pinion teeth cut by the 

GENEROID process which leads to greater 

capacity of torque and durability than conventional 

gears due to a larger number of teeth in 

gear (1 totally and 2 partially in gear) 

• Hypoid Pinion assembled on conic roller bearings, 

which absorb the axial and radial forces 

and a cylindrical roller bearing at the top 

of the head, which absorbs the radial loads. 

• Box-Unit of Satellites and Crown, mounted 

on conic roller bearings. 

• Satellites and Planetary gears with straight 

conic teeth obtained by precision forging. 

• Notch of the Pinion with fine teeth of an evolving 

profile, rolled cold for greater resistance 

and durability with a small screw angle to 

couple under pressure, with the Fork of the 

Universal Joint, the-reby avoiding the loosening 

of the pinion nut when the vehicle is subject 

to a high vibration level. 

• Lubrication channels positioned at stra-tegic 

points, to ensure efficient lubrication of the 

gears and bearings at lower speeds. 

4 MAINTENANCE MANUAL

Exploded View 


5

Exploded View Nomenclature 

ITEM DESCRIPTION ITEM DESCRIPTION 

01 Differential Box 

02 Bearing Cover 

03 Screw - Fastening Bearing 

04 Washer 

05 Satellite Box - Flange Half 

06 Satellite Box - Single Half 

07 Satellite 

08 Satellite Thrust Washer 

09 Differential Crosspiece 

10 Planetary Item 

11 Satellite Thrust Washer 

12 Screw Fastening 

13 Roller Bearing Cone (Satellite Box 

- Flange Half) 

14 Roller Bearing Cone (Satellite Box 

- Single Half) 

15 Roller Bearing Cover (Satellite 

Box - Flange Half) 

16 Roller Bearing Cover (Satellite 

Box - Single Half) 

17 Adjusting Ring 

18 Locking Pin 

19 Pinion 

24 Elastic Ring 

25 Pinion Box Adjusting Wedge 

26 Pinion Box 

27 Roller Bearing Cover (Inside 

Pinion) 

28 Roller Bearing (Outside Pinion) 

29 Roller Bearing Cone (Outside 

Pinion) 

30 Pinion Roll Adjusting Wedge 

31 Roller Bearing Cone (Inside Pinion) 

32 Universal Joint Fork 

33 Dust Deflector 

34 Pinion Sealer 

35 Pinion Nut 

36 Screw (Fastening Pinion Box) 

37 Washer (Fastening Pinion Box) 

38 Washer (Fastening Pinion Box) 

39 Washer (Fastening Crow) 


Identification 

The unit has ID plates on which the basic product 

specifications are written. 

MODEL 

CUST Nº 

PART Nº 

RATIO 

SERIE Nº 

DATE 

(Model) 

(Customer Number) 

(Product Number) 

(Differential Reductions) 

(Serial Number) 

(Manufacturing Date) 

Before starting service operations, identify the 

unit to be repaired, looking at the ID plates fastened 

to the differential box frame. This information 

will allow correct identification of the spare 

parts required, allowing the execution of a quicker 

and more accurate service operation. 

DIFFERENTIAL ID PLATE 

FRAME ID PLATE 

AXLE UNIT ID PLATE 

ID PLATE 


7

Disassembly 

Disassembly of Differential 

Before starting service operations, identify the 

unit to be repaired, looking at the ID plates fastened 

to the frame and Differential Box. 

• Remove the draining belly, located on the 

lower surface of the frame and drain all the 

existing oil (figure 01). 

Figure 03 

• Remove the half shafts. 

• Disconnect the cardan shaft. 

PLUG 

Figure 01 

• Loosen the nuts, the lock washers and conic 

washers of the tap bolts fastening the half 

shafts. 

IMPORTANT: 

In order to remove the conic washers, support 

a brass bar (with O 38 mm) in the depression 

existing at the center of the flange 

of the half shaft and hit it with a bronze 

hammer (figure 02) or use and auxiliary nut, 

hitting with a hammer on the hexagonal nut 

(figure 03). 

Removal of the Differential 

A - Loosen the differential setscrews and remove 

them. 

B - Loosen the differential from the frame using 

a suitable support and a jack. (figure 04). 

IMPORTANT: 

If it is necessary to use eyebolts, the flange of 

the differential box has threaded holes for this 

purpose. The same setscrews of the differential 

can be used in this operation. 

If necessary, apply firm blows with a rubber 

or plastic hammer to release the differential 

from the adhesive effect of the chemical joint. 

Never insert a wedge or chisel between the differential 

box and the frame so as not to cause 

irreparable damage to their surfaces. 

CAUTION: 

1 - Do not hit directly on the half shaft. 

2 - Do not insert wedges or chisels be-tween 

the half shaft and the wheel to avoid 

irreparable damage to these parts. 

Figure 02 

Figure 04 


Disassembly 

C - Install the unit in an appropriate support (figure 

05) 

Removal of the Bearing Covers 

A - Remove and discard the pins, cotter pins 

or lock of the adjusting rings of the satellite 

box (figure 07). 

Figure 05 

D - Measure the value of the gearing gap of 

the teeth of the crown/pinion pair. See the 

section GEARING GAP ADJUSTMENT 

(figure 06). 

CAUTION: 

Before executing the measurement, 

remove all the oil existing on 

the teeth of the crown and pinion 

with one of the solvents indicated 

in the CLEANING section and follow 

the instructions in the DRYING section 

Figure 07 

B - Loosen the retaining washers and screws 

of the bearing covers and mark the original 

positions of the covers. 

C - Manually remove the bearing covers (figure 

08). 

Figure 06 Figure 08 


9

Disassembly 

D - Manually remove the adjusting rings (figure 

09). 

Disassembly of the Satellite Box 

A - Check, before the disassembly, if the halves 

of the satellite boxes (single and with a 

flange), have a marked assembly position. 

If not, mark them so that the original position 

is maintained in the reassembly (figure 

11). 

B - Loosen the setscrews of the two halves of 

the box. 

Figure 09 

E - Remove the satellite box with safety and 

place it on a bench (figure 10). 

Figure 11 

C - Separate the two halves of the box and remove 

the internal components, in the sequence 

indicated (figures 12, 13, 14 and 15). 

Figure 10 

Figure 12 

Figure 13 


Disassembly 

E - Only if necessary, remove the crown using 

an appropriate extractor or a press. Sup- 

-port the crown between metal or wooden 

blocks and press the half box through the 

crown (figure 17). 

Figure 14 

Figure 17 

Figure 15 

F - If it is necessary to replace the crown and it 

is attached by rivets, use the following procedure 

(L-147): 

D - If necessary, loosen and remove the retaining 

washers, nuts and bolts of the crown 

(figure 16). 

Figure 22 

Figure 16 


11

Disassembly 

G- Remove the hypoid crown, using an appropriate 

extractor or a press (figure 22). 

B - Remove the universal joint fork using an extractor 

(figure 26). 

IMPORTANT: 

Do not remove the fork with hammer blows, 

as this may warp it, besides making deep 

marks on the roller bearings, preventing 

their possible reuse. 

Figure 23 

Figure 26 

C - Remove and discard the pinion sealer (figure 

27). 

Figure 24 

Disassembly of the Pinion Box and the 

Pinion Rod 

A - Immobilize the universal joint fork with an 

appropriate tool and loosen the pinion nut 

(figure 25). 

IMPORTANT:. 

In order to remove the sealer easily and safely, 

insert a screwdriver between the sealer 

flange and the pinion box and make a lever 

movement at several points so that it comes 

out gradually, without damaging the pinion 

box. 

Figure 27 

Figure 25 

D - Loosen the setscrews of the pinion box and 

remove them together with the washers. 


Inspeção 

E - Remove the pinion box (figure 28). 

F - Remove and fasten the adjusting wedges of 

the pinion box, so that their original position 

is main-tained in the reassembly, if reusing 

these components. 

G - Remove the pinion using an appropri-ate 

extractor or a press. Support the flange of 

the pinion box on wooden or metal blocks 

and press the pinion through the box (figure 

30). 

Figure 28 

Note: 

Hit the pinion box a few times with a rubber 

or leather hammer to loosen it. The pinion 

box has threaded holes for using eyebolts. 

The same setscrews of the pinion box can 

be used in this operation (figure 29). 

CAUTION: 

Upon using the press, wear safety 

goggles. 

IMPORTANT: 

Do not remove the pinion with hammer blows, 

as the effect of the blows may damage 

the roller bearings, preventing possible reuse 

of them. 

H - Manually remove the front roller bearing 

cone. 

Figure 29 

CAUTION: 

Do not insert wedges of chisels between 

the pinion box and the differential 

box to avoid irreparable 

damage to these parts, as well as 

to the adjusting wedges. If the adjusting 

wedges are in good condition, 

measure them and keep them 

for the reassembly. 

Even if the wedges are damaged, measure 

the thickness of the packet 

and record the dimension, as it will 

be used as a reference in reassembling 

the pinion box. 

Figure 30 

I - Remove, if necessary, the front and back roller 

bearing covers, using an appropriate extractor 

or a press (figure 31). 

Figure 31 


13

Preparation for assembly 

J - Remove from the pinion rod manually the 

adjusting wedges of the roller bearings. (figure 

32). 

Cleaning 

The unit can undergo external washing, in order 

to facilitate its removal and disassembly. In 

this case, all the openings should be covered 

to avoid the possibility of water or humidity entering 

the unit. 

Figure 32 

K - Remove, if necessary the back roller bearing 

cone using an appropriate extractor or 

a press (figure 33). 

L - Remove and discard, if necessary, the elastic 

ring, using appropriate pliers. 

IMPORTANT : 

We do not recommend washing the unit with 

water after it has been disassembled. When 

this cleaning system is used, the water is retained 

in the parts. This can cause oxidation 

(rust) in critical parts and allow the circulation 

of these rust particles in the oil. This 

practice can lead to premature wear of the 

roller bearings, gears and other parts. Thuds, 

the unit should be totally disas-sembled 

as it cannot be cleaned suitably in another 

manner. 

NEVER USE GASOLINE 

Wash all the components which have ma-chined 

or rectified surfaces (gears, roller bearings, 

wedges, crosspiece) using appropriate solvents 

with a petroleum base, such as: diesel oil 

of kerosene. 

Wash the cast parts (satellite box, bearing covers 

and inside of the differential box) using the 

afore mentioned solvents. CAUTIONly remove 

all the joint particles. See the LIQUIDJOINT 

section. 

Clean the breathing plugs CAUTIONly (an air 

jet can be used). If it is blocked or damaged, 

replace it. 

Figure 33 

M - Remove, if necessary, the pilot roller bearing, 

using an appropriate press (figure 34).. 

CAUTION: 

Blocked plugs cause an increase in 

internal pressure in the unit, being 

able to lead to oil leaking by the 

sealers. 

Figure 34 



Drying 

T he parts should be completely dry, immediately 

after the cleaning, which must be performed 

using soft, clean cotton cloths. 

Note : 

Compressed air can also be used for drying 

the parts, except for the roller bearings. 

B - Wear (with visible lowering ) on the race of 

the cover or cone and/or deep indentations 

(figure 35). 

C - Cracks or breakages in the seats of the cover 

and/or cone, or in the surface of the 

conic rolls. 

CAUTION: 

The recess chambers must be very 

clean and dry to avoid later contamination. 

Inspection 

It is of paramount importance to inspect all the 

unit components fully and CAUTIONly, before 

they are reassembled. This inspection will reveal 

the parts with excessive wear or cracks, 

which should be replaced. 

Figure 35 

D - Signs of friction in the conic roll cage (figure 

36). 

Inspection of the Roller Bearings 

Inspect the roller bearings of cylindrical rollers 

and/or conic rollers (covers and cones) including 

those which were not removed from the 

seats upon which they were mounted, and replace 

them if they have any of the following defects: 

A - Excessive wear on the wide surface of the 

conic rolls, with almost total elimination of the 

central lowering, and/or a worn radius, with a 

sharp edge, on the wide surface of the rolls: 

(figure 34). 

Figure 36 

E - Corrosion ( caused by chemical action ) or 

cavity in the functioning surfaces (figure 

37). 

Figure 37 

6 - Splintering or scaling in the surface of the 

cover and/or cone (figure 38). 

Figure 34 

Figure 38 


15


Inspection of the Crown and Pinion Pair 

Inspect these gears, noting if there is any wear 

or damage, as cracks, depressions, splits or 

splinters. Also check the seats of the roller bearing 

cones and the notch of the pinion. 

Note : 

The CROWN and PINION are machined gears 

coupled in pairs, to ensure the ideal 

contact position between their teeth. So, if it 

is necessary to Exchange a damaged crown 

or pinion, both the gears of the pair should 

be replaced. 

Note : 

O ar comprimido pode ser empregado também 

na secagem das peças, exceto para os 

rolamentos. 

A - Internal surfaces on both the halves of the 

satel-lite box; 

B - Support surface of the thrust washers of satellites 

and planetary gears; 

C - Crosspiece legs; 

D - Planetary gear teeth and notches; 

E - Satellite teeth and holes. 

IMPORTANT: 

If it is necessary to replace a damaged satellite 

or planetary gear, Exchange all the 

gears, including the thrust washers. The 

combination of new and old parts can lead 

to premature failure of the unit. 

Inspection of the Unit Satellite Box 

Inspect the components of the differential 

system and replace the parts which have depressions, 

cracks, excessive ovalization in 

holes and semi-holes or excessive wear tin 

the work surfaces. Also check the work areas 

specified below (figure 39). 

Inspection of the Half Shaft 

Check if there are cracks and excessive wear 

in the notches or teeth and also if there is ovalization 

in the flange holes. 

Inspection of the Differential Box 

Observe if there are fractures in any surface 

or burrs in the machined regions. 

SATELLITE BOX 

INSIDE 

SATELLITES 

AND WASHERS 

Inspection of the Universal Joint Fork 

Replace the universal joint fork, if it has excessive 

wear in the working area of the sealer 

lips. 

Inspection of the Frame 

Check if there are signs of cracks, loose tap 

bolts, burrs or notches in the machined surfaces. 

PLANETARY GEAR 

WASHER 

CROSSPIECE 

INSPECT 

NOTCH 

Figure 39 



Stocking 

The parts, after washing, drying and inspec- 

-tion, should be immediately reassembled or 

covered with a fine layer of the oil specified in 

the LUBRICATION section, in order to avoid 

oxidation. 

The parts which had top be stocked should be 

covered with a good layer of oil or any other 

substance preventing corrosion and kept in a 

closed box or the equivalent, protecting them 

from dust, humidity and rust (except for the 

components already protected with paint or 

zincing, etc). 

Maintenance - Recovery 

Replace all the parts which are worn or damaged, 

always using original components of 

MERITOR, to ensure a maintenance service 

with satisfactory results, as using parts which 

are not original will reduce the useful life of 

the unit. 

For better guidance, we indicate some basic 

check criteria, for purposes of repairs and/or 

replacement of the components: 

Recovery Through Welding 

For the sake of safety and prevention of the 

life of the maintenance to be executed, ME- 

RITOR recommends that repairs are not performed 

through welding, which can affect the 

structural integrity of the components, as well 

as cause distortions in those already submitted 

to the processes of thermal treatment. 

Repairing with welding can only be approved 

where rigorous controls are imposed with 

equipment which, usually, is only to be found 

in the manufacturing sites. 

IMPORTANT : 

Upon deciding if a part should be repaired 

or destroyed, bear in mind that we, the 

manufacturers, never hesitate to destroy a 

part which is in any way doubtful. 

A - Replace the nuts and bolts with rounded edges 

of the head and/or a damaged thread. 

B - Replace the lock washers, plain wash-ers, 

elastic rings, elastic pins and cotter pins. 

C - Whenever the unit is reconditioned, also replace 

the pinion sealer. 

D - Remove all the joint particles. See the CHE- 

MICAL JOINT section. 

E - Remove notches, stains, burrs or other imperfections 

of the machined surfaces. 

F - The threads must be clean and unda-maged 

to obtain an exact adjustment and the 

correct tightening torque. 

G - Whenever possible, use a press to reassemble 

the parts. 

H - Tighten all the fastening or locking com-ponents 

with the values specified in the TOR- 

QUE TABLE section. 

I - Remove the notches or burrs from the differential 

box or frame. 


17

Liquid lock 

MERITOR adopted a liquid lock as its main 

locking element and, therefore, this section 

describes the care required for the suitable 

use of this liquid adhesive. 

The liquid locks are cured in the absence 

of air and as they are liquid quickly and uniformly 

fill all the space existing between the 

threads, allowing a safer and more efficient 

locking to be obtained than the existing conventional 

systems. 

FEATURES OF THE LIQUID LOCKS 

PRODUCT 

TYPE 

COLOR 

CURE TIME 

TORQUE 

LOCTITE 

271 

241/1243 

221 

RED 

BLUE 

VIOLET 

2 HOURS 

6 HOURS 

6 HOURS 

THREE 

BOND 

1334 

1305 

RED 

GREEN 

6 HOURS 

6 HOURS 

MEDIUM 

HIGH 

Disassembly 

Execute the disassembly of the units locked 

originally with a liquid lock, using the normal 

procedures of mechanical disassembly. 

CAUTION: 

Do not use impact wrenches or hammer 

blows, to avoid damaging the head of these 

components. 

If the removal of a nut, for example, becomes 

difficult due to the wear of its head 

or because it requires a rather high force 

to loosen it, reduce the resistance of 

the liquid lock heating the head of this 

component at 150 ºC, approximately, at 

the same time as trying to loosen it. This 

procedure must be done slowly, to avoid 

thermal tension in the components of this 

unit. 

Cleaning 

CAUTIONly clean the threaded hole and the 

fastening thread (screw, nut or tap bolt), totally 

eliminating the dirt, oil, grease or humidity. The 

removal should be executed with a cleaning 

agent, as trichloroethylene or another chlorine 

solvent. 

Reassembly 

Before starting this operation, check the application 

places specified in the REASSEMBLY 

section. If there are, in this unit, for example, 

screws which were not removed during the disassembly 

of the unit, but had previous application 

of a liquid lock, it is necessary to check 

the tightening condition of each one of them. In 

this case apply the tightening torque (minimum) 

recommended by MERITOR. If the screw does 

not turn, its condition is satisfactory. If it turns, 

remove it and execute the procedures described 

in this section. 


Liquid lock 

Procedure For Application 

A - Apply the liquid lock so as to fill all the gap 

between the threads. In the case of internal 

threads (with a blind hole), apply 4 to 6 

drops in the fillets of the threaded hole (fig- 

-ure 41). 

Note : 

When the hole is not passing, apply a liquid 

lock in the thread of the hole, as when the 

lock is applied to the thread of the screw 

and it is inserted, the air existing in the hole 

makes a contrary pressure, expelling the liquid 

of the lock. 

Figure 41 

B - Tighten the fastening components with the 

values specified in the TIGHTENING TOR- 

QUES section. 


19

Chemical joint 

Description 

The CHEMICAL JOINT is a material with pasty 

consistency, which is cured at ambient temperature, 

forming a resistant joint. 

The joints used by MERITOR are: 

174 and 574 (LOCTITE) and NEUTRAL SI-LI- 

CONE (DOW CORNING 780, LOCTITE 5699, 

TREE BOND 1216, RHODIA 567 or 666). 

Cleaning 

CAUTIONly clean both the junction surfaces, 

eliminating the residue of the previous joint, 

dirt, oil, grease or humidity. This residue should 

be removed using a spatula or sandpaper, 

followed by cleaning with a solvent free of oil as 

xylol, or toluene or methylethylketone. 

Avoid causing grooves in these surfaces, as 

they can lead to later leakage. 

Procedure For Application 

A - Apply a continuous fillet of approximately 3 

mm in diameter when the joint is NEUTRAL 

SILICONE or apply with a brush when it is 

FAG-3 , all over one of the coupling surfaces 

and all the fastening holes, to en-sure a 

total Seal which avoids leakage; 

FILLET APPROX. 

3 mm IN DIAMETER 

Drying 

Before application, ensure that the junction surfaces 

are perfectly dry. 

Figure 42 

CAUTION: 

Excessive application causes the 

joint mass to migrate inside the 

unit, and also leads to difficulties 

in future disassembly. Failures in 

applying the joint Cord may cause 

future leakage. 

B - After the application, join the two surfaces 

immediately, so that the joint cord spreads 

in a uniform manner; 

C - Then, tighten the fastening components 

with the values specified in the TIGHTE- 

NING TORQUES section. 


Assembly 

Assembly of Pinion Box 

A - Install the roller bearing covers ( back and 

front ) in the pinion box in a press, with the 

box supported on wooden or metal blocks 

or use a suitable tool (figures 42 and 43). 

Note: 

The same procedure is used to Install both 

the covers. 

B - Assemble the back roller bearing cone, 

using a suitable tool or a press. Ensure that 

the cone is perfectly aligned in the pinion 

(figure 44). 

COUPLING 

ROLLER 

BEARING 

COVER 

Figure 42 

Figure 44 

C - Assemble the pilot roller bearing, using a 

suitable tool or a press (figure 45). . 

Figure 42 

CAUTION: 

- Check that the cover seats are clean and 

free of burrs. 

- Check during the assembly that no wrenching 

of the pinion box material is occurring. 

- Ensure that the covers are perfectly supported 

in their seats. 

Figure 45 

CAUTION: 

Ensure that the roller bearing is perfectly 

supported in the pinion. In the assembly use 

an appropriate coupling which only rests in 

the internal race of the roller bearing. 


21

Assembly 

D - Install the new elastic Ting using appropriate 

pliers (figure 46). 

Roller Bearings of the Pinion 

The control of the pre-load avoids that the roller 

bearings operate with excessive pres-sure (it 

reduces their useful life) or with a gap (it generates 

a noise and reduces the useful life of the 

differential). 

The pre-load is obtained by installing 1 (one) 

selective wedge between the cones of the roller 

bearings of the pinion (see figure 48); 

Figure 46 

E - Lubricate the roller bearing covers and cones 

with the oil recommended in the LU- 

BRICATION section. 

F - Install, in the pinion rod, the roller bearing 

spacers. 

ADJUSTING WED- 

GES OF THE ROL- 

LER BEARING 

Note : 

The spacers control the adjustment of the 

preload of the pinion roller bearings. 

G - Position the pinion in the box. 

H - Press the front roller bearing and check the 

pre-load (figure 47). 

Figure 48 

Identification of the Adjusting Wedge 

of the Pinion Roller Bearings 

A series wedges is available for this adjustment 

which are differentiated by the thickness, as indicated 

in tables “A”, “B”, “C” and “D”. 

The differential uses a wedge which will ensure 

a pressure between the roller bearings, which 

is equivalent to the following resisting torques: 

MODEL 

120 

USED ROLLER 

NEW ROLLER BEARINGS BEARINGS 

N.m lbf.pol N.m lbf.pol 

2,2 - 3,3 20 - 30 1,3 - 2,0 12 - 18 

145/147 

0,5 - 5,0 

5 - 45 1,1 - 3,4 10 - 30 

155 

1,7 - 4,0 

15- 35 1,1 - 2,3 10- 20 

Figure 47 

160 

0,5 - 5,0 

5 - 45 1,1 - 3,4 10 - 30 

185 

0,5 - 5,0 

5 - 45 1,1 - 3,4 10 - 30 

Note : 

DO NOT INSTALL the pinion sealer before 

adjusting the pre-load of the pinion roller 

bearings. 

CAUTION: 

These values should be obtained without 

the sealer being assembled in the pinion 

box. 


Assembly 

MODEL RS 120 

MODEL 145/147 

PART N° THICKNESS PART N° 

THICKNESS 


THICKNESS 

028079 

12,12 

028089 

12,37 

028820 

17,77 

028826 

17,92 

028080 

12,14 

028090 

12,40 

028821 

17,79 

028827 

17,95 

028081 

12,17 

028091 

12,42 

028822 

17,82 

028828 

17,97 

028082 

12,19 

028092 

12,45 

028823 

17,84 

028829 

18,00 

028083 

12,22 

028093 

12,47 

028824 

17,87 

028830 

18,02 

028084 

12,24 

028094 

12,50 

028825 

17,89 

028831 

18,05 

028085 

028086 

12,27 

12,30 

028095 

028096 

12,52 

12,55 

Table B 

028087 

12,32 

028097 

12,57 

028088 

12,34 

028098 

12,60 

Table A 

MODEL 155 

MODEL 160 / 185 


THICKNESS 


THICKNESS 

029050 

18,72 

029057 

18,90 

029684 

13,03 

029693 

13,18 

029051 

18,74 

029058 

18,92 

029685 

13,05 

029694 

13,20 

029052 

18,77 

029059 

18,95 

029686 

13,06 

029695 

13,23 

029053 

18,79 

029060 

18,98 

029687 

13,08 

029696 

13,25 

029054 

18,82 

029061 

19,00 

029688 

13,10 

029697 

13,28 

029055 

18,85 

029062 

19,03 

029689 

13,11 

029698 

13,31 

029056 

18,87 

029690 

13,13 

029699 

13,33 

Table C 

029691 

029692 

13,15 

13,16 

029700 

029701 

13,35 

13,38 

Table D 

MODEL 

120 

RECOMMENDED RANGE 

MM 

INCHES 

17,48 - 17,53 0,688 - 0,690 

IMPORTANT: 

The parts are identified through the recording 

of the thickness on one of the surfaces. 

145/147 

155 

160 

17,87 - 17,97 

18,79 - 18,92 

13,18 - 13,28 

0,704 - 0,708 

0,740 - 0,745 

0,519 - 0,523 

We recommend that the start assembly is performed 

with the wedges situated in the range 

recommended in table “E”, which will allow the 

adjustment desired to be obtained immediately 

(in most cases): 

185 

13,18 - 13,28 

0,519 - 0,523 

Table E 


23

Assembly 

Pinion Roller Bearing Pre-Load Adjustment 

The pre-load value of the pinion measured as 

per fig. 49 is the one indicated in the table below: 

MODELO 

120 

145/147 

155 

160 

185 

Method Using Press 

Note : 

If a press is not available, use the assembly 

method with the yoke (universal joint fork). 

A - Lubricate all the pinion roller bearings with 

the oil specified in the LUBRICATION section. 

B - Press the cone of the front roller bearing 

and rotate the pinion box several times to 

ensure a suitable seating between covers 

and cones. Maintain the pinion box under 

the press with an applied load. 

MODEL 

120 

145/147 

155/160/185 

USED ROLLER 

NEW ROLLER BEARINGS BEARINGS 

KG LB KG 

LB 

3,4 - 5,1 

0,7 - 6,7 

2,1 - 4,8 

0,5 - 5,1 

0,5 - 5,1 

7,7 - 11,8 2,0 - 3,1 4,6 - 6,9 

1,7 - 15,0 1,5 - 4,6 3,3 - 10,0 

4,5 - 10,6 1,3 - 2,8 3,0 - 6,0 

1,3 - 11,4 1,1 - 3,5 2,5 - 7,6 

1,3 - 11,4 1,1 - 3,5 2,5 - 7,6 

LOAD (TON) 

6 (MAX) 

C - Wind a cord around the pilot diameter 

of the pinion box with a dynamometer 

(balance of good quality), tied at its 

end (figure 49). 

11 

14 

D - Pull the dynamometer horizontally and observe 

the value (pounds or kilos) recorded 

on its scale. 

Note : 

Note the value recorded with the box rotating 

and not the start value. The start value 

gives a false reading. 

Method Without Using Press 

If a press is not available during the service 

operation, use the following procedure: 

A - Lubricate all the hypoid pinion roller bearings 

with the oil specified in the LUBRICA- 

TION section; 

B - Install the fork/flange of the universal joint 

(without the pinion sealer); 

C - Immobilize the pinion (through the fork/flange 

of the universal joint) using a suitable device; 

D - Tighten the pinion nut with the minimum 

value specified in the TIGHTENING TOR- 

QUES section; 

E - Turn the pinion box several times to en-sure 

a suitable seating between covers and 

cones; 

F - Wind a cord around the pilot diameter of the 

pinion box with a dynamometer (balance of 

good quality), tied at its end. (figure 49); 

G - Pull the dynamometer horizontally and observe 

the value (pounds or kilos) recorded 

on its scale; 

Note : 

Note the value recorded with the box rotating 

and not the start value. The start value 

gives a false reading. 

H - If after tightening with the maximum limit of 

torque, the desired pre-load is not obtained, 

replace the wedges by thinner ones and re- 

-peat the checking procedure; 

I - Remove the fork/flange of the universal joint 

and continue to reassemble the differential. 

Figure 49 


Assembly 

Pinion Assembly Depth Adjustment 

- Without the aid of a Special Tool 

The depth adjustment of the pinion aims to position 

the pinion related to the crown to obtain 

an ideal contact between the teeth of these gears 

(figures 50 and 51); 

WEDGES 

eXAMPLE 

ms 124 

Figure 50 Figure 51 

INCREASE THE 

REDUCES THE 

DEPTH 

DEPTH 

dn: 173,0 

Figure 52 

- With the aid of Special Tool 140 / 145 

CAUTION: 

In the operations described below, check 

the cleanness, mainly: 

1 - Of the contact surfaces between the 

components of the special tool; 

2 - Of the contact surfaces of the components 

of the special tool with the two 

boxes of the differential and the pinion, 

which is fundamental. 

A series of wedges is available to adjust the 

depth of the pinion, which are differentiated by 

the thickness. (figure 52) 

MODEL 

120 

145/147 

145 (NOVO) 

155 

PART N° 

029101 

029345 

029099 

029311 

028807 

028808 

028809 

028810 

029522 

029523 

029524 

029525 

028453 

028454 

028455 

THICKNESS (mm) 

0,20 

0,10 

0,05 

0,05 

0,08 

0,12 

0,20 

0,50 

0,06 

0,12 

0,25 

0,50 

0,08 

0,12 

0,25 

Adjust the depth of the pinion with the aid of the 

following components of the tools (figure 53): 

1. Centralized shaft 

2. Pinion simulator 

3. Adapter 

4. Circlet 

5. Knurled nut 

6. Clock support 

7. Wedge 

8. Centralizing disk 


160/185 

029390 

029391 

029386 

029387 

0,05 

0,12 

0,20 

0,50 

185 

220328814 

22038815a 

2203B8816 

2203C8817 

0,05 

0,12 

0,20 

0,50 

Figure 53 


25

Assembly 

Install in the pinion simulator the pinion back 

roller bearing adapter (figure 54). 

1. Adapter 


Install on the other surface of the pinion box the 

front roller bearing (figure 57). 

Figure 54 

Install in the adapter back roller bearing of the 

pinion (figure 55). 

1. Adapter 

Figure 57 

Place the circlet of the pinion front roller bearing 

and the knurled nut, tightening the latter 

manually (figure 58). 

1. Circlet 

2. Knurled nut 

1 

Figure 55 

Install the pinion box with the surface which will 

fit in the differential box turned downwards on 

the pinion back roller bearing (figure 56). 

Figure 58 

Figure 56 


Assembly 

Check that the contact surfaces of the pinion 

box and the differential box are clean and free of 

scratches or protuberances. 

Install the pinion box without the height adjustment 

wedges in the differential box (figure 59). 

Turn the differential box 180º degrees. 

Check that the housing bearings of the satellite 

roller bearings and centralizing disks of the 

tools are perfectly clean, lubricating them afterwards 

with a slight oil film. 

Install the wedge on top of the pinion simulator 

(figure 61). 

1. Wedge 


3. Bearings 

Figure 59 

Place four bolts and apply a start tightening in a 

crosswise sequence. 

Then, with a torquemeter and in the same sequence, 

apply the final tightening, as per the 

torque specified in the table page 46) (figure 

60). 

Figure 61 

Install the centralizing disks with their respective 

shaft in the housing bearings of the satellite 

box roller bearings (figure 62). 



3. Centralizing shaft 

Figure 60 

Figure 62 


27

Assembly 

Install in the support a centesimal comparator. 

Place the support and the feeler gauge of the 

comparator on the wedge at the point of the pinion 

simulator - standard surface adjusting the 

instrument dial to reading “0” (zero) (figure 63). 

This value is called the nominal gauge of the 

differential in question. 

The nominal gauge is the distance existing between 

the touching surface of the pinion back 

roller bearing and the crown center. (figure 64). 

1. Wedge 

2. Clock support 

3. Comparator 


(CN) Nominal 

GAUGE 

Figure 64 

Figure 63 

MODEL 

120 

(CN) NOMINAL GAUGE 

193,68 

Then, with the support of the comparator firmly 

supported on the wedge, on the point of the pinion 

simulator, place the feeler gauge on the 

centralizing shaft. 

Next, move the feeler gauge transversally to 

the centralizing shaft, until the instrument pointer 

indicates a maximum value. This value which 

indicates that the feeler gauge is exactly on 

the diameter of the centralizing shaft. 

Note the maximum value (Vm) indicated by the 

pointer of the comparator (figure 64). 

145/147 

155 

160 

185 

195,28 

219,08 

235,00 

254,00 

Check and Note the number recorded at the 

top of the pinion. This value indicates, in accordance 

with the signal which precedes it, how 

many hundredths of millimeters must be added 

to or subtracted from the maximum value (Vm) 

obtained in the reading of the comparator clock 

(figure 65). 

Figure 64 

Figure 65 


Assembly 

We list below some cases as an example to 

determine the quantity of wedges to be installed, 

between the pinion box and the differential 

box: 

1. Recording (0) zero at the top of the pinion. 

A - Measurement obtained in the clock reading; 

B - Recording at the top of the pinion; 

0.58 mm 

0.00 mm+ 

Total 0.58 mm 

Install the same quantity of wedges ob-tained 

in the reading of the clock (A) 0.58 mm (figure 

66). 

3. Recording (-06) at the top of the pinion 


B - Recording at the top of the pinion (-06); 

0.58 mm 

0.06 mm- 

Total 0.52 mm 

In this case, install the quantity of wedges (0.52 

mm) resulting from subtracting A - B (figure 68). 

Figure 66 

2. Recording (+06) at the top of the pinion 


B - Recording at the top of the pinion (+06); 

0.58 mm 

0.06 mm+ 

Total 0.64 mm 

In this case, install the quantity of wedges (0.64 

mm), resulting from adding A + B (figure 67). 

Figure 68 

Method without Special Tool 

If there is no exchange of crown and pinion pair, 

maintain the wedge pack of the pinion box. 

If there is an exchange of pair, check the reading 

in the old pinion and the new pi-nion (figure 

68). Calculate the difference and add or 

remove wedges of the original pack. 

Figure 67 

Figure 68 


29

Assembly 

EXAMPLE OF CALCULATION No. 1 

Old Pinion +06 

New Pinion -03 

Difference 09 

Action: Remove 0.09 mm from the origi-nal 

wedge pack. 


> 

Old Pinion = -06 

> 

New Pinion = +03 

Difference 09 

Action: Add 0.09 mm to the original wedge 

pack. 

Note: If the original wedge pack is lost, start 

from the nominal pack of: 

C - Pinion variance (VP) 

All the pinions have an individual variance related 

to their DN, which is recorded at the top 

of their head. This variance is expressed in 

thousandths of an inch and preceded by a + 

or - sign. 

If there is no exchange of crown and pinion pair, 

maintain the wedge pack of the pinion box. 

If there is an exchange of pair, check the recording 

in the old pinion and the new pinion (figure 

68). Calculate the difference and add wedges 

to or subtract them from the original pack. 


Old Pinion +6 

New Pinion -3 

Difference 9 

Action: Remove 0.009” from the original 

wedge pack. 

MODEL 

120 

145/147 

155 

THICK. (mm) 

0,96 

0,96 

THICKNESS 

(inches) 

.020 + .010=.038” 

.020 + .010=.038” 

0,906 (2).010 +(2).005=.038” 


> 

Pinhão Velho = -6 

> 

Pinhão Novo = +3 

Diferença 9 

5 Adjustments of Differential 

L-147 

The process for adjusting this unit is basically 

the same as for models 140 and 145, except 

that the wedges must be executed in inches, as 

these gears are NOT metric. 

Action: Add 0.009” to the original wedge 

pack l. 

Note: If the original wedge pack is lost, start 

from the nominal pack of: 0.90 mm (0.035”). 

A - Identification of the Pinion Box Adjustment 

Wedges 

MODEL 

120 

CODE 

THICKNESS 

MM INCHES 

029101 0,20 0,008 

029101 0,10 0,004 

029101 0,5 0,002 

029101 0,3 0,001 

B - Nominal dimension of pinion assembly: 

DN = 7,625” 


Assembly 

Assembly of the Pinion Sealer 

1 - Install the pinion sealer as indicated below: 

a - If the sealer does not have the external diameter 

rubberized, apply a sealing paste (industrial 

adhesive 847 3M) on the external 

surfaces of the pinion sealer. 

CAUTION: 

Ensure that the lips of the sealer 

are free of dirt or particles which 

may cause possible leakages. 

Installation of the Pinion Box in the 

Differential Box 

A - Install the pinion box wedges already selected, 

in the differential box with 2 guide pins 

(figure 71). 

Note : 

Place the thickest wedges at the ends of the 

pack and the finer ones in the middle. 

b - Press the pinion sealer with a coupling or 

install it with the device. 

Ensure that the sealer flange is level with the 

top of the pinion box. It is important that the 

coupling diameter is larger than that of the sealer 

(figures 69 and 70). 

Figure 71 

B - Install the pinion box. If necessary use a 

rubber or leather hammer (figure 72 ). 

Cassete Type 

for Shafts 145 - 155 

Tri-labial 

Industrial Adhesive 

Figure 69 

Figure 72 

Figure 70 


31

Assembly 

C - Apply sealing paste FAG-3 to the thread of 

the pinion box setscrews. 

D - Install and tighten the washers and setscrews 

of the pinion box, with the value specified. 

See the TORQUES TABLE. (figure 

73 ). 

IMPORTANT: 

Do not use a hammer to install the fork of 

the universal joint, as it can be damaged. 

6. With a torquemeter on the pinion nut, check 

the resisting torque value (pre-load) to 

turn the pinion. Increase if necessary the 

torque applied to the pinion nut (until the 

maximum limit allowed), to handle the values 

specified. (figure 75). 

MODEL 

USED ROLLER 

NEW ROLLER BEARINGS 

BEARINGS 

N.m lbf.pol N.m lbf.pol 

120 

2,2 - 3,3 

20 - 30 

1,3 - 2,0 

12 - 18 

145/147 

0,5 - 5,0 

5 - 45 

1,1 - 3,4 

10 - 30 

Figure 73 

155 

1,7 - 4,0 

15- 35 1,1 - 2,3 10- 20 

160 

0,5 - 5,0 

5 - 45 1,1 - 3,4 10 - 30 

185 

0,5 - 5,0 

5 - 45 1,1 - 3,4 10 - 30 

5. Immobilize the fork of the universal joint 

with a suitable tool and tighten the pinion 

nut with the value specified. See TORQUES 

TABLE. (figure 74 ). 

Figure 75 

Figure 74 


Assembly 

Assembly of the Satellite Box 

A - Apply the lubricating oil specified in the LU- 

BRICATION section in all the components 

of the satellite box, before installing them; 

B - Heat the crown in warm water, at the temperature 

of approximately 70°-80°C, during 

10 minutes, to allow it to be placed manually. 

D - Install the fastening components of the crown 

and tighten the screws with the tor-que 

specified in the TORQUES TABLE. 

Note: 

Apply to the screws HIGH TORQUE locking 

paste (LOCTITE 271 or THREE BOND 1305). 

See section LIQUID LOCK. 

CAUTION: 

Wear appropriate gloves to handle 

the heated part. 

E - Assemble the new cones of the roller bearings 

in the two halves of the bipartite satellite 

box, using a suitable tool and a press 

(figure 77). 

IMPORTANT: 

The installation of the crown with pre-heating 

ensures the correct seating of it in all 

the common contact area with the satellite 

box, as when the crown is as-sembled on 

the press or turned on the satellite box, there 

may occur a wrenching of metallic particles 

which are lodged between these 2 

parts, causing misalignment of the crown 

and making final adjustments of the differential 

difficult. See the ADJUSTMENTS 

section. 

C - Install the crown in the flange half of the satellite 

box. If the crown is not seated satisfactorily, 

repeat step 2 (figure 76). 

Figure 77 

CAUTION: 

- Check that the cone seats are clean and 

without burrs; 

- Check, during the assembly operation 

that no material wrenching is occurring in 

the box; 

- Ensure that the cones are perfectly supported 

on their respective seats. 

F - Position the planetary gear with its thrust 

washer in the flange half box. 

G - Assemble the crosspiece, the satellites with 

the respective washers (figure 78). 

Figure 76 


33

Assembly 

J - Initially install four setscrews of the satellite 

box at equally spaced points and tighten 

them with the torque specified. See the 

TORQUES TABLE. 

K - Assemble the remaining screws and tighten 

them with the torque indicated in item 10. 

See the TORQUES TABLE. 

Figure 78 

Note: 

Apply to the screws HIGH TORQUE locking 

paste (LOCTITE 271 or THREE BOND 1305). 

H - Then position the planetary gear opposite 

its thrust washer in the box – flange half (fig- 

-ure 79). 

Figure 79 

I - Install the satellite box – single half, ob-serving 

the original alignment (figure 80). 

MARCAS 

Figure 80 


Assembly 

Check of the Resistance to Rotation of 

the Satellite / Planetary Gear Unit 

C- Install the tool coupling it to the planetary 

gear notch (figure 83). 

Torque specified: 

68 N.m (50 lb.ft) maximum. 

Note : 

A suitable tool for checking can be made 

from a cut solar half shaft, with a nut welded 

to its end (figure 81). 

Figure 83 

D - Place a torquemeter at the end of this device 

and check the resistance to the rotation of 

the satellite/planetary gear unit. The value 

should be less than that specified (figure 84). 

Figure 81 

A - Place a protector in the vise (filing block) of 

bronze, aluminum or plastic to protect the 

crown. 

B - Fasten the satellite box in the vise (figure 

82). 

Figure 84 

E - If the value exceeds that specified, disassemble 

the satellites and planetary gears of 

the satellite box. 

F - Check the parts to discover the reason for 

the excessive resistance. Repair the cause 

or change the parts. 

G - After fixing the problems, assemble the parts 

and repeat the procedure from A to D. 

Figure 82 


35

Assembly 

Assembly of the Satellite Box Unit in 

the Differential Box 

A - Support the covers on the cones and assemble 

the unit in the differential box (figure 85). 

CAUTION: 

If it is not possible to turn the rings manually 

(without applying force) it is because 

they are out of position. Remove the covers 

and reposition the adjusting rings to avoid 

irreparable damage to the differential box 

and bearing covers. 

• Assembly of the Satellite Box/Adjustment 

of the Gears. (figure 88) 

Figure 85 

B - Place the adjusting rings in the bearings turning 

them manually until touching the roller 

bearings (figure 86). 

ring side 

of coro 

ring opposite 

side 

Figure 88 

A quick and accurate way to assemble the satellite 

box and adjust the gap of the gearing 

(between teeth) and the pre-load of the roller 

bearings, is as follows: 

Figure 86 

C - Position the bearing covers tightening them 

slightly (figure 87). 

A - Assemble the satellite box, tightening the 

ring on the crown side until eliminating the 

gap. Then, loosen it by three or four castles 

(value of approximation for gap between 

teeth). 

B - Tighten the ring opposite until eliminating 

the gap of the roller bearings. Next, tighten it 

by two to three castles (new roller bearings) 

or one to two castles (used roller bearings). 

Then, check the gap of the gearing (see table 

page 39). If necessary, adjust it loosening 

and tightening the ad-justments rings as 

in the figure . 

C - The pre-load indicated (1.7- 3.5 N.m (15-35 

lbf inch)) will be obtained with this procedure. 

(figure 89) 

Figure 87 


Assembly 

increases 

gap 

reduces 

gap 

Figure 89 

IMPORTANT: 

In order to move the rings in the final adjustments, 

always use a “T” type bar or ordinary 

bars which engage in to opposite castles, as 

illustrated in the figure. Never hit the castles 

with hammers or chisels, as this may cause 

irreparable damage to the adjusting rings. 

(figure 90) 

D - Apply the liquid lock (Loctite 271 or Three 

Bond 1305) to the thread of the bearing 

setscrews. 

E - Install and tighten the bearing setscrews 

with the respective washers, with the value 

specified. See the TORQUES TABLE. 

F - Adjust the pre-load of the satellite box roller 

bearings. 

specified: 1.7- 3.5 N.m 

G - Adjust the gearing gap. See the ADJUST- 

MENTS section. 

H - Check the contact of the teeth of the crown/ 

pinion pair. See the ADJUSTMENTS section. 

I - Install the cotter pin and/or lock of the ad- 

-justing rings with the torque specified. See 

the TORQUES TABLE. (figure 91). 

Figure 91 

Figure 90 


37

Assembly 

Installation of the Unit Differential Box 

in the Frame 

A - Apply neutral silicone in the opening of the 

frame. See the CHEMICAL JOINT section 

(figure 92). 

B - Position the differential in the frame. Use a 

hydraulic Jack or a block and tackle. 

Figure 92 

CAUTION: 

Do not try to place the differential in the frame 

using a hammer, as the flange may be 

deformed and cause a leakage. 

C - Apply high torque liquid lock to the thread 

of the differential box setscrews. See the 

LÍQUID LOCK section. 

D - Install the differential box setscrews with 

their respective washers and alternately tighten 

the first four spaced at 180º and then 

the others with the specified torque: 

MODEL 

BOLT 

NUT 

N.m lbf pé N.m lbf pé 

120 

145/147 

155 

160 

95-150 

270-330 

270-330 

270-330 

70-110 

200-245 

200-245 

200-245 

185 

270-330 


Adjustments 

Gearing Gap 

A - Check the gearing gap of the crown/pinion 

pair, using the following procedure: 

B - Support the pointer of a comparator clock in 

the tooth of the crown (figure 93). 

E - If necessary increase or reduce the gearing 

gap, by loosening the adjusting ring on the 

right side and in the same proportion tightening 

the left side or vice versa, as required 

(figure 94). 

Figure 93 

C - Immobilize the pinion, manually move the 

crown in both directions of rotation and take 

the reading. The gap value should be as per 

the table below. 

D - If necessary increase or reduce the gearing 

gap, by loosening the adjusting ring on the 

right side and in the same proportion tightening 

the left side or vice versa, as required 

(figure 94). 

Figure 94 

Note: 

It is important to maintain the propor-tion 

between tightening and loosening, i.e.: the 

same amount that is loosened in one ring 

must be tightened in the other so that the 

pre-load of the satellite box roller bearings 

is maintained 

MODEL 

120 

145/147 

155 

160 

185 

GAP 

milímeters 

21 - 45 

21 - 45 

0,26 - 0,50 

0,25 - 0,51 

0,25 - 0,41 

IMPORTANT: 

If reusing the crown/pinion pair, it is advisable 

to maintain the original gearing gap. 


39

Adjustments 

Contact of the Crown and Pinion Teeth 

Check of the Differential Contact Models 120 - 

145 - 147 - 155 - 160 - 185 

Checking Process 

A - Apply yellow iron oxide (diluted in fine oil) to 

some of the crown teeth (figure 95). 

C - Check if the contact obtained by the manual 

process complies with the standard (figure 

97). If not, use the correction methods indicated 

in the item “Incorrect Contacts”. 

Note: 

- Upon obtaining the correct contact on the 

convex side (forward gear), the contact on 

the concave side (reverse gear) will automatically 

be satisfactory (figure 97). 

- With the application of load in the vehicle, 

this contact will practically encompass all 

the length of the tooth, approaching its 

toe (figure 98). 

Figure 95 

B - Brake the crown, with the aid of a lever or 

lath simulating a load and turn the pinion 

manually, until obtaining the impression of 

contact on the convex side (forward gear) 

of the crown teeth (figure 96). 

Figure 97 

Figure 96 

Figure 98 


Adjustments 

Satisfactory Contact 

To make it easier, we indicate the terminol-ogy 

used in this section (figure 99). 

The contact standard for the manual process 

indicates that the gears are in the correct position, 

resulting in a contact area between the toe 

and heel/top and root of the tooth. Figure 97. 

Incorrect Contact 

Variances Concerning the Height of the 

Tooth 

If the pinion is not at the correct depth, the contact 

can have variance related to the height of 

the tooth. In this case, correct its position varying 

the thickness of the wedge pack under 

the pinion box. (figures 101 and 102) 

Figure 99 

If the convex side is satisfactory, consider the 

contact of the concave side of the tooth (reverse 

gear) automatically accepted. 

The standard with application of load shows 

the contact resulting when the gears approved 

by the manual process undergo a load action 

(work operation). The contact area extends 

to all the length of the tooth and the top of the 

standard approaches the top of the crown tooth 

(figure 100). 

Figure 101 

IT REDUCES THE THICK- 

NESS OF THE WEDGE 

PACK 

Figure 102 

IT INCREASES THE THI- 

CKNESS OF THE WEDGE 

PACK 

Figure 100 


41

Adjustments 

CONTACT 

OBTAINED 

Level 

Contact 

Bottom 

Contact 

MEANING 

It indicates that the pinion is very far 

from the crown, resulting in a contact 

very near the top of the tooth (figure 

101). 

It indicates that the pinion is very 

near the crown, resulting in a contact 

very near the tooth root (figure 102). 

HOW TO CORRECT 

Approach the pinion reducing the thickness 

of the adjusting wedge Pack of 

the pinion box (see the Pinion Assembly 

Distance Adjustment section). This will 

make the contact move to the tooth root 

(figure 101). 

Separate the pinion increasing the 

adjusting wedge pack thickness of the 

pinion (see the Pinion Assembly Distance 

Adjustment section). This will make 

the contact move to the top of the tooth. 

(figure 102). 

Variances Concerning the Tooth Length 

Then, check if the contact has variance related 

to the tooth length. If so, alter the crown depth, 

varying the gearing gap. 

CONTACT 

OBTAINED 

Toe 

End 

Contact 

Heel 

End 

Contact 

MEANING 

It indicates that the crown is very 

near the pinion, resulting in a contact 

very near the toe of the tooth (figure 

103). 

It indicates that the crown is very far 

from the pinion, resulting in a contact 

very near the heel of the tooth (figure 

104). 

HOW TO CORRECT 

Separate the crown increasing the gearing 

gap (if necessary, until the maximum 

allowed) so that the contact area 

moves in the direction of the tooth heel, 

approaching in the manner indicated in 

figure 97 (see the Gearing Gap Adjustment 

section). 

Approach the crown reducing the gearing 

gap (if necessary, until the minimum 

allowed) so that the contact area moves 

in the direction of the tooth toe, approaching 

in the manner indicated in figure 

97 (see the Gearing Gap Adjustment 

section). 

Contacto Extremo de 

la Punta 

Figure 103 Contacto Extremo 

Figure 104 

Talón 


Adjustments 

Check of the Differential Contact 

Model RS120 

The hypoid pinion and crown teeth of the differential 

RS120 are cut by the conventional process. 

Check the contact of the teeth of these gears 

using the same correction procedure specified 

for the models 120, 145/147, 155, 160 and 185, 

but considering the contact standards illustrated 

in figures 103, 104, 105, 106, 107, 108. 

STANDARD FOR APPLYING 

load 

Figure 107 

STANDARD FOR 

MANUAL PROCESS 

Figure 105 

BOTTOM CONTACT 

Figure 108 

IMPORTANT: 

Upon noting that the contacts are correct, 

lock the adjusting rings with a pin or cotter 

pin. 

CAUTION: 

In the assembly, a cotter pin may be used 

where originally the pin was assembled, but 

NEVER assemble a pin in the hole where a 

cotter pin was used. 

LEVEL CONTACT 

Figure 106 


43

Main Satellite Box Blocking System 

Warning and Danger Messages 

Read and observe all the Warning and Precaution 

alert messages. They contain information 

which can help to prevent serious personal injury, 

damage to components, or both. 

WARNING: 

In order to prevent serious injury to the eyes, 

always wear safety goggles when executing 

services or maintenance in the vehicle. 

Description 

Some traction shafts of ArvinMeritor are equipped 

with a Blocking System of the Main Satellite 

Box (DCDL). This locking of the satellite 

box is operated by an air drive mechanism and 

assembled in the differential unit. When activated, 

the drive mechanism moves a locking ring 

sliding it on a notch in the half shaft. When coupled, 

the locking ring links the half shaft to a 

second notch which exists on one of the sides 

of the satellite box. Both the traction wheels 

are now simultaneously coupled, not allow-ing 

the differential action of the main satellite box. 

Figure 109 

Note : 

The ArvinMeritor differential unit models 

equipped with a locking system of the main 

satellite box are made in metric dimensions. 

When these differential units are maintained, 

it is very important to use metric size 

tools suited to the fastening components. 

Removal of the Differential Unit of the Shaft 

Frame. 

Before the differential unit can be removed or installed, 

the locking system of the main satellite box 

must be activated and maintained in the activated 

or locked position. In the “locked” position, there 

will be a sufficiently large gap between the locking 

ring and the shaft frame to allow the removal or 

installation of the differential unit. 

Note: 

If the half shaft is removed to tow the vehicle 

and the differential is in the unlocked or 

uncoupled position, install the half shaft of 

the left side in the shaft frame before continuing. 

Execute the following steps to reinstall 

the half shafts in the shaft frame: 

1. Remove the protection, if used during the towing 

of the vehicle, of the wheel hubs. 

2. If the traction shaft is equipped with a locking 

system of the main satellite box, activate the 

system to the unlocked or uncoupled position. 

Install the half shaft with two notches 

and new joints in their place as follows: 

A. Place the half shaft and joint in the hub and 

frame until the half shaft touches the gearing 

ring. 

B. Lower, raise and turn the half shaft by the 

flange until the notch of the half shaft and the 

gearing ring are engaged. 

C. Push the half shaft inside the frame of the 

shaft until the half shaft touches the planetary 

gear of the main satellite box. 

D. Lower and turn the half shaft by the flange 

until the notch of the half shaft and of the 

planetary gear of the differential are engaged. 

E. Place the half shaft completely inside the 

frame until the flange and joint are adjusted 

against the wheel hub. 



Gearing or Locking of the DCDL 

WARNING: 

During the disassembly of the DCDL or the 

removal of the differential unit, when the 

DCDL is in the locked or engaged position 

and one of the vehicle wheels is raised from 

the ground, do not turn the motor on or couple 

the transmission. The vehicle may move 

and cause serious personal injury. The 

components may also be damaged. 

Park the vehicle on a level surface. Block the 

wheels to prevent the vehicle from moving. 

Support the vehicle on safety supports. Do 

not work under a vehicle supported only by 

a jack. The jack can slip or break. Serious 

personal injury and damage to the components 

may occur. 

CDDL FASTENED BY SCREWS 

housing hole for the 

manual gearing screw 

manual 

gearing 

screw 

PLUG and 

joint 

housing hole for the 

plug and joint in the 

lower joint 

air line 

cylinder 

cover 

electric 

cable 

position of operation 

hole 

Figure 111 

Manual Method 

Use the following manual method to couple the 

mechanism of the DCDL in the locked position: 

If an air line is not available or the differential unit 

is stocked for later use, use this manual gearing 

method for the DCDL. Figure 110 and Figure 111. 

housing 

hole 

air 

hose 

threaded CDDL 

Cylinder 


Figure 110 

1. Park the vehicle on a level surface. Block the 


2. Remove the drainage plug from the frame 

and drain all the lubricant. 

3. Use a jack to raise the wheel of the left side 

of the traction shaft. 

4. Place a safety support under the spring seat 

of the left side to maintain the vehicle in the 

raised position. 

5. Disconnect the cardan shaft of the differential 

unit input fork. 

6. Disconnect the air line of the vehicle of the 

differential locking drive system between 

shafts and of the main satellite box. 

7. Remove the connection and the joint from 

the central hole of the cylinder fastened by 

a thread or of the flanged cylinder fastened 

by screws of the DCDL. 

8. Remove the manual gearing screw from the 

housing hole in the cover of the cylinder fastened 

by screws or in the box of the mechanism 

with a cylinder fastened by a thread. 

Figure 110 and Figure 111. 

Note: 

For the drive mechanism unit of the DCDL 

fastened by screws, the housing hole of 

the plug and joint is on the opposite side 

of the housing hole of the manual gearing 

screw. Figure 111. 

9. Install the plug and the joint of the lower housing 

threaded hole in the cylinder cover or 

in the box of the mechanism fastened by a 

thread. 


45


10.Install the manual gearing screw in the threaded 

hole in the center of the cylinder or in 

the threaded hole of the cylinder cover, as 

built. 

CAUTION 

There will be a small resistance 

of the spring which you will feel 

when threading the manual gearing 

screw. If you feel a high resistance 

before reaching the locked 

or engaged position, stop tightening 

the screw, or the cover, fork 

and screw thread may be damaged. 

11. Turn the manual adjustment screw to the 

right until the head is approximately 6 mm 

(0.25”) from the cylinder cover. Do not turn 

the screw beyond its normal stop. 

A high resistance in the screw indicates that 

the notch of the gearing ring and of the satellite 

box are not aligned or engaged. To align the 

notches, use the following procedure: 

A. Turn the left Wheel to align the notch of the 

gearing ring with the satellite box while you 

turn the manual gearing screw. 

B. When you feel a normal slight resistance of 

the spring again in the gearing screw, the 

notched items will be engaged. Continue 

to turn the ma-nual gearing screw until the 

head is approximately 6 mm (0.25”) from 

the cylinder cover. The screw will now be 

in the position for maintenance and the locking 

system of the differential will be engaged. 

12. Remove the differential from the shaft frame. 

13. Release the locking of the differential by 

removing the manual gearing screw and 

seal the cover of the cylinder fastened by a 

screw or the threaded cylinder. 

Method with the Auxiliary Air Source 

1. Park the vehicle on a level surface. Block the 


2. Use a jack to raise the wheel on the left side 

of the shaft. Place a safety support under the 

left side of the frame to maintain the vehicle 

in this raised position. 

bosseS 

Figure 112 

3. Remove the drainage plug from the lower 

part of the frame and drain the lubricant. 

4. Disconnect the cardan shaft of the input fork. 

5. Disconnect the air line of the vehicle which 

activates the blocking system of the differential 

between shafts and of the main satellite 

box. 

6. Install a connector for a suitable air line in 

the main satellite drive mechanism unit. 

7. Install the air line in the connector. 

CAUTION 

When using an auxiliary air source 

to engage the DCDL, the source 

should be maintained connected 

until the removal of the differential 

of the shaft frame. Do not disconnect 

the auxiliary air line or 

reduce the pressure for the DCDL 

before removing the differential 

unit from the shaft frame. The components 

may be damaged. 

8. The air line should supply the mechanism 

with a regulated pressure of 120 psi (827 

kPa). 

9. Check if the DCDL is engaged. 

10. Remove the differential unit from the shaft 

frame. 

11. Close the air source to the DCDL. 

12. Disconnect the air line of the main satellite 

box drive mechanism unit connector. 

Main Satellite Box and its Blocking System 

Drive mechanism unit with a cylinder fastened 

by a Thread. 

The current project of the locking fork does not 

use elastic pins. Bosses on the internal surface 

of the fork maintain the gearing ring in place. 

Figure 112. 



1. Check that the drive system is released and 

that the manual gearing screw was removed 

from the drive mechanism cylinder. 

2. Hit the gearing ring with a rubber hammer to 

loosen it and remove it from the gearing fork. 

Figure 113 

5. Place the piston and cylinder unit in a vise 

protected by bronze filing blocks. Remove 

the piston and “O” ring from inside the cylinder. 

Use a small bar placed through the hole 

of the top of the cylinder and push the piston 

outwards. It may be necessary to use a small 

rubber hammer CAUTIONly to hit and remove 

the piston outwards. Figure 116. 

suitable 

diameter 

bar 

gearing ring fork 

gearing ring 

Figure 113 

3. Remove the locking mechanism sensor switch, 

if used, and its locking nut from the differential 

box. Figure 114. 

Figure 116 

6. CAUTIONly remove the “O” ring from the piston. 

Use the point of a small tool to facilitate 

this removal. Be very CAUTION not to damage 

the piston. Figure 117. 

Figure 114 

4. Remove the locking system drive piston and 

cylinder unit turning it to the left. Figure 115. 

Figure 117 

7. Check the “O” ring to identify any type of damage 

as cuts, splits. 

• If the “O” ring is damaged, replace it by a 

new ring when you reassemble the components. 

8. Clean and inspect all he drive mechanism 

unit parts. 

Figure 115 


47


9. Pull the locking fork drive shaft and remove it 

from the differential box. Figure 118. 

gearing fork 

drive 

shaft 

10. Remove the spring from the differential box 

locking fork drive shaft spring. Figure 119. 

MOLA DO EIXO DE 

ACIONAMENTO 

box of the dcdl 

cast in the differential 

box 

Figure 118 

Figure 120 

This unit is disassembled in the same manner 

as in the differentials without the satellite box 

locking mechanisms. 

Drive Mechanism Unit Fastened by Screws 

1. To remove the gearing ring from the block- 

-ing mechanism, withdraw the two retaining 

elastic pins of the ring until they are level 

with the internal surface of the locking ring 

fork. Figure 121. 

2. If necessary, remove the blocking drive mechanism. 

drive 

shaft 

spring 

Figure 119 

11. If elastic pins are used, use a hammer and 

a bronze punch to remove the pins from the 

covers of the bearing and the adjusting ring. 

If cotter pins or screws are used, remove 

them. 

12. Remove the adjusting rings and setscrews 

and washers from the bearing covers. Mark 

one of the bearing covers and the differential 

box so that these parts are assembled in the 

same position when reassembling the differential. 

13. Raise and remove the satellite box unit from 

the differential box. Figure 120. 

ELASTIC PINS - Withdraw 

until they are facing 

the internal surface 

of the gearing ring fork 

Figure 121 

A. Remove the mechanism sensor switch and 

its locking nut. 

B. Remove the four screws and washers which 

fasten the cylinder cover. Remove the cover. 

In the Series 160 differentials, remove 

the copper joint. Figure 122. 

C. Remove the drive mechanism piston and 

cylinder. 

D. Remove the locking ring fork shaft. It may 

be necessary to use heat to separate the 

fork shaft. 



Note: 

Some models use a Silastic seal instead of 

a plain washer in step E. There is also an 

elastic pin installed in the drive shaft and 

it is used as a stop for the spring. It is not 

necessary to remove this elastic pin during 

a normal disassembly. 

E. Remove the spring from the drive shaft and 

the plain washer. 

F. Remove the drive fork and continue with 

step 11 in the previous procedure. 

DCDL Mechanism Unit with Fastening by 

Thread. 

Install the blocking drive mechanism unit of the 

satellite box after it has been installed and the 

gears and roller bearings have been adjusted. 

The drive mechanism of the satellite box blocking 

fastened by thread is shown in figure 123. 

THREADED VERSION UNBLOCKED 

drive shaft and 

springs 

electrical connection 

for sensor 

fastening position 

of manual gearing 

screw 

piston 

cylinder 

screws and 

washers four 

edges 

cover, joint of copper 

under cober 

series 160 only 

gearing 

ring 

fork 

“o” ring 

Figure 122 

Figure 123 

Installation of Satellite Box Blocking Drive 

Mechanism Unit 

WARNING: 

Upon applying the silicone chemical joint, a 

small quantity of acid vapor will be released. In 

order to prevent serious per-sonal injury, ensure 

that the work area is well ventilated. Read 

the manufacturer’s instructions before using 

the silicone chemical joint, and then follow the 

instructions CAUTIONly. If your eyes are attained 

by the material of the silicone chemical 

joint, follow the manufacturer’s emergency procedures. 

Make an appointment with an ophthalmologist 

as quickly as possible. 

Be CAUTION when using Loctite adhesive to 

avoid serious personal injury. Read the manu- 

-facturer’s instructions before using this product. 

Follow the instructions CAUTIONly to 

prevent irritation of the eyes and skin. 

1. Install the locking ring in the drive shaft in 

the differential unit. The “L” from section 

of the fork and the hole for the drive shaft 

should be turned towards the cylinder housing 

side in the differential box. Figure 124 

“L” form fork 

external 

surface 

Figure 124 


49


2. Compress the spring of the locking drive 

shaft and install it between the rear part of 

the locking fork and the inside wall. Figure 

125. 

conic end 

drive shaft spring 

drive cylinder 

Figure 127 

Install the spring 

behind the fork 

Figure 125 

3. Align the spring and the hole of the locking 

ring fork with the hole of the drive shaft in 

the differential box. 

4. Install the drive shaft through the hole in the 

differential box, the locking ring fork and the 

spring. Figure 126. 

7. Apply a continuous fillet of 1.5 mm (0.06”) in 

diameter of seal for flanges of Loctite with 

number ArvinMeritor 2297-D-7076, around 

the threads of the DCDL cylinder. 

8. Turn the piston and drive cylinder unit to the 

right until reaching the bottom of the housing 

in the differential box. Figure 128. 

gearing ring 

fork 

drive 

shaft 

Figure 126 

Figure 128 

5. If necessary, lubricate a new “O” ring with 

lubricating oil of the shaft. Install the “O” ring 

in the piston channel. 

6. Install the piston unit with the “O” ring inside 

the drive cylinder with the beveled side 

turned towards the bottom of the cylinder. 

Push the piston until it is at the bottom of the 

cylinder. Figure 127. 

9. Position the locking ring on the fork. The 

larger notch of the locking ring should be 

turned towards the main satellite box. Use 

a rubber hammer to hit the locking ring until 

it goes through the bosses of the drive fork. 

Figure 129. 



10. Engage the notch of the locking ring with 

the notch of the satellite box. Insert the manual 

gearing screw by the top of the drive 

cylinder of the mechanism to move the gearing 

ring in the direction of the satellite box. 

Turn the gearing ring as required to align 

the notches. Figure 130. 

12. With the locking ring in the engaged position, 

install the sensor switch in its threaded 

hole in the front part of the differential box. 

Figure 131. 

large 

notches 

in the 

satellite 

box of the 

main differential 

Figure 131 

bosses in the gearing 

ring fork 

Figure 129 

11. Turn the manual gearing screw to the right 

until its head is approximately 6 mm (0.25”) 

from the cylinder top. Do not turn the screw 

beyond its normal stop. The screw will have 

raised the piston to the correct work position 

and the locking system of the main satellite 

box will be completely engaged. 

Note: 

The differential unit should be in its locked 

position t install the half shaft in the shaft 

frame. 

drive cylinder of 

the threaded 

dcdl 

13. Connect a multimeter to the sensor switch. 

Select the resistance measurement function 

in the appliance. With the DCDL engaged, 

the circuit should be closed, showing less 

than 1 ohm of resistance. If the resistance 

is above 1 ohm, check the sensor. 

A. Check that the fork is aligned with the sensor 

switch when it is in the engaged position. 

B. Check that the connection wires are loose. 

The connector should be firmly placed in its 

hous-ing. 

C. Check that the sensor switch is totally pressed 

against the differential box. 

• If the resistance is greater than 1 ohm 

after these checks, replace the sensor 

switch. 

DCDL Mechanism Unit with Fastening by 

Screws. 

Install the drive mechanism after the differential 

unit has been assembled and the adjustments 

of the gears and roller bearings are ready. 

The drive mechanism of the type fastened by 

screws is shown in Figure 132. 


Figure 130 


51


DCDL FASTENED BY SCREWS 

4. Apply the thread lock Loctite 222 to the 

threads of the drive shaft of the locking ring 

fork. 

5. Install the locking fork in its assembly position 

in the differential box. Figure 134. 

1 - Plain washers or chemical 

joint as required 

2 - Cylinder 

3 - Electrical connection for 

the sensor 

4 - Air line 

5 - “O” Ring 

6 - Piston 

7 - Disengaged 

8 - Engaged 

9 - Copper joint 

10 - Pin 

11 - Gearing ring fork 

12 - Gearing ring 

13 - Drive shaft and spring 

Figure 132 

Figure 134 

6. Maintain the gearing ring fork in its position. 

Install the return spring of the drive shaft 

through the opening for the shaft in the differential 

box, through the fork hole and inside 

the housing for the spring. Figure 135. 

1. In the differential models with locking ring 

fork with elastic pins, install the two elastic 

pins at the ends of the fork. Insert the pins 

until they are touching the internal side of 

the fork. Figure 133. Do not install the pins 

in their end position at this moment. 

Apply Thread 

Chemical Lock 222 

gearing ring fork 

elastic pin 

drive 

shaft 

internal surfaces 

of the 

fork 

Figure 135 

Figure 133 

2. If the blocking pin of the spring was removed 

from the drive shaft head, reinstall the 

pin now. 

3. In the models without the spring blocking 

pin, assemble the locking fork in its position. 

7. Slide the drive shaft on the spring. Install 

the drive shaft in the locking ring fork. Tighten 

with 27-34 N.m (20-25 lb-ft). 

8. Install the copper joint or apply the Silastic 

seal, with number ArvinMeritor 1199-Q- 

2981, on the touching surface of the cylinder. 

Figure 136. 



VERSION FASTENED BY SCREWS 

9. Lubricate the “O” ring with shaft lubricating 

oil. Install the “O” ring in its channel in the 

piston. CAUTIONly install the air piston inside 

the air cylinder. Figure 136. Do not damage 

the “O” ring. 

10. Install the air cylinder inside the housing in 

the differential box. Check that the pilot in 

the piston entered the housing of the drive 

shaft. Figure 137. 

Apply Chemical 

Joint 

cylinder 

cover 

screw 4-6 

lb-ft (6,6- 

8,6 N/M) 

drive 

shaft 

air 

cylinder 

piston and 

“o” ring 

Install plain washer or apply 

chemical joint Figure 136 

VERSÃO FIXADA POR PARAFUSO 

11. Install the copper joint, if used, in the housing 

inside the air cylinder cover. Place the 

cover in its position on the cylinder so that 

the air inlet is turned upwards when the differential 

unit is installed in the shaft frame. 

Install the cover with the four setscrews and 

retaining washers. Tighten the screws with 

5.5-8.5 N.m (4-6 lb-ft). Figure 138. 

12. Apply a fillet of Silastic seal, number Arvin- 

Meritor 1199-Q-2981, in the joint between 

the cylinder and frame of the differential. 

13. Slide the gearing ring inside the locking ring 

fork and engage the notch of the locking 

ring with the notch of the satellite box. Use a 

manual actuation screw to move the locking 

ring on the satellite box. 

14. Maintain the gearing ring in its locked or engaged 

position and hit the two elastic pins at 

the ends of the fork until they are level with 

the external surfaces of the fork. Figure 139. 

15 While the locking ring is in its locked position, 

place the sensor switch in the threaded 

hole and with the locking nut loose. 

GEARING RING 

GEARING 

FORK 

VERSION 

MANUAL 

GEARING 

SCREW 

Figure 138 

cilindro e 

pistão 

piloto 

Figure 139 

eixo de 

acionamento 

Figure 137 

16. Connect a multimeter to the sensor switch. 

Select the resistance function in the appliance. 

Turn the switch in the direction of the clock 

pointers until you read on the appliance a 

resistance infinite or less than 1 ohm. Give 

the switch an additional turn and tighten the 

locking nut with 35-45 N.m (25-35 lb-ft). 


53


Covers Stopping Up the Satellite Box Blocking 

System 

For differentials without the main satellite box 

blocking system, assemble a protection cover 

and plug to stop up the hole for the sensor as 

below. 

Assembly of the protection cover unit for 

DCDL fastened by screws. 

1. Install the washer and the plug in the threaded 

hole for the sensor switch. Tighten the 

plug with 60-74 N.m (45-55 lb-ft). Figure 140. 

2. Apply the silicone chemical joint to the assembly 

surface of the protection cover in the 

differential box. 

3. Install the four washers and screws. Tighten 

the screws with 10-12 N.m (7.4-8.9 lb-ft). Figure 

140. 

COVER IN THE VERSION FASTENED BY THREAD 

(Apply adhesive Loctite 518 to the cover threads)) 

SENSOR 

SWITCH 

PLUG 

WASHER 

WASHER 

SCREW 

COVER IN THE 

VERSION FASTE- 

NED BY SCREWS 

(Apply Chemical 

Joint) 

Figure 140 

Assembly of the protection cover unit for 

DCDL fastened by thread. 

1. Apply the adhesive Loctite 518 to the protection 

cover threads. 

Assembly of the Previous Differential Unit 

in the Shaft Frame 

WARNING: 

Solvents for cleaning can be flammable, 

poisonous and cause burns. Examples of 

solvents for cleaning are: carbon tetrachloride, 

emulsion types and solvents with a petroleum 

base. Read the manufacturer’s instructions 

before using the cleaning solvent, 

and then CAUTIONly follow the instructions. 

Also obey the following procedures. 

• Wear safe protection for the eyes; 

• Wear clothes which protect your skin; 

• Work in a well-ventilated area; 

• Do not use gasoline or solvents which contain 

gasoline. Gasoline can explode; 

• You will be able to use a hot solution tank 

or alkaline solution. Read the manufacturer’s 

instructions before using tanks with a hot solution 

and alkaline solutions. Then, CAUTIO- 

Nly follow the instructions. 

Note: 

When you install the differential unit in the 

shaft frame, the locking ring should be in 

the coupled or engaged position. This can 

be obtained by applying air pressure to the 

cylinder or by using the manual gearing 

screw. See the procedure in this section. 

The differential should be in the engaged or 

coupled position to allow it to be installed 

in the shaft frame After installing the differential 

unit in the shaft frame, activate the 

mechanism to the unlocked or disengaged 

position to allow the installation of the half 

shaft of the left side. 

Manual Method 

1. Use cleaning solvent and cloths to clean the 

internal part and the assembly surface of the 

flange of the differential unit in the shaft frame. 

2. Check the shaft frame to identify if it is damaged. 

If necessary, repair or replace the shaft 

frame. 

3. Check if there are tap bolts loose on the assembly 

surface of the differential unit. Remove 

and replace the tap bolts when required. 

Apply adhesive to the threaded holes of the 

tap bolts. Install and tighten the tap bolts with 

204-312 N.m (150-230 lb-ft). 

4. The locking system of the satellite box should 

be in the coupled or engaged position before 

installing the differential unit in the shaft frame. 

See the procedure in this section. 

5. Install the differential unit in the shaft frame. 

6. Install and tighten the setscrews of the differential 

unit in the shaft frame with the torque 

specified. 

7. Install the half shafts of the left side and the 

right side. 



Note: 

When the manual engaging screw is removed 

from the service position of the actuator 

center of the DCDL, the main satellite 

box locking system will be disengaged or 

uncoupled. 

8. Remove the long engaging screw of the 

DCDL of the cylinder with fastening by 

thread or of the cylinder with fastening by 

screws 

9. Clean the plug, joint, cylinder cover and the 

threaded hole of the cylinder cover center 

of the DCDL fastened by screws, or in the 

cylinder cen-ter of the DCDL fastened DRI- 

VE MECHANISM OF DCDL FASTENED 

BY THREAD HOUSING HOLE CYLINDER 

Figure 142 MANUALby thread. 

10. Check that the sealing joint is under the 

screw head. 

11. Install the manual gearing screw in its housing 

in the versions of the DCDL fastened 

by thread or fastened by screws. Figure 141 

and Figure 142. 

A. In the DCDL fastened by screws, remove 

the short plug and the joint of the housing 

hole. Install the short plug and joint in the 

service hole in the center of the DCDL. Figure 

141. 

B. In the DCDL fastened by thread, install the 

short screw or plug in the housing hole located 

in the top of the drive mechanism box. 

Figure 142. 12. Tighten the plug with 44-55 

lb-ft (60-75 N.m). Tighten the manual gearing 

screw 30- 38 N.m (22-28 lb-ft) for cylinders 

of the DCDL fas-tened by screws and 

10-15 N.m (7-11 lb-ft) for mechanisms of 

the reverse type DCDL fastened by thread. 

MANUAL 

GEARING 

SCREW 

DCDL UNIT FASTENED BY SCREWS 

plug aND JOINT 

AIR 

LINE 

sensor 

DRIVE MECHANISM OF DCDL FASTENED 

BY THREAD 

housing hole 

cylinder 

air hose 

manual gearing 

screw 

Figure 142 

13. Connect the air line of the vehicle to the main 

satellite box blocking drive mechanism. 

14. Install the electrical connection in the sensor 

switch located in the differential box under 

the actuator unit. 

15. Remove the safety support under the shaft. 

Lower the vehicle to the ground. 

16. Fill the shaft with lubricating oil. 

17. Proceed to check the locking system of the 

main satellite box as described in this section. 

Method with Auxiliary Air Supply 

1. Use a cleaning solvent and cloths to clean 

the internal part of the frame and the assembly 

flange of the differential unit. 

2. Check the differential frame to identify damage. 

If necessary, repair or replace the 

shaft frame. 

3. Check if there are loose tap bolts in the assembly 

flange of the differential unit. Remove 

and replace the tap bolts when re-quired. 

Apply adhesive to the threaded holes. 

Install and tighten the tap bolt with 204-312 

N.m (150-230 lb-ft). 

4. Connect an air line to the blocking mechanism 

of the main satellite box. 

5. The air line should supply the mechanism 

with a regulated pressure of 827 Kpa (120 

Psi). 

6. Check if the DCDL is engaged or 

HOLE FOR HOUSING 

OF THE PLUG AND 

JOINT IN THE LOWER 

PART 

POSITION OF THE HOLE 

FOR MANUAL GEARING 

SCREW 

Figure 141 


55


7. Install the differential unit in the shaft frame. 

8. Install and tighten the setscrews of the differential 

unit with the torque specified. 

9. Install the half shaft of the left side and the 

right side. 

10. Remove the coupling of the air line from the 

main satellite box locking mechanism unit. 

11. Clean the plug, joint, cylinder cover and the 

threaded hole of the cylinder cover center 

of the DCDL fastened by screws, or in the 

cylinder center of the DCDL fastened by 

thread. 

12. Tighten the plug with 60-75 N.m (44-55 lb- 

-ft). Tighten the manual engagement screw 

with 30-38 N.m (22-28 lb-ft) of the cylinders 

of the DCDL fastened by screws and 10-15 

N.m (7-11 lb-ft) for the DCDL type fastened 

by thread. 

13. Connect the air line of the vehicle to the drive 

mechanism of the main satellite box blocking. 

14. Install the electrical connection to the sensor 

switch located in the differential box below 

the actuator unit. 

15. Remove the safety support under the shaft. 

Lower the vehicle to the ground. 

16. Fill the shaft with lubricating oil. 

17. Proceed to check the main satellite box 

blocking system as described in this 

section. 

Checking the Main Satellite Box Blocking 

System. 

1. Place the transmission of the vehicle in the 

disengaged position. Turn on the engine so 

that the pneumatic system of the vehicle attains 

the normal pressure level of functioning. 

WARNING: 

During the disassembly of the DCDL, when 

it is in the locked or engaged position and 

one of the wheels is off the ground, do not 

turn on the engine or couple the transmission. 

The vehicle may move and cause serious 

personal injury and damage to the 

components. 

2. Place the drive switch of the differential blocking 

installed in the vehicle cabin in the unlocked 

or disengaged position. 

3. Drive the vehicle at 8-16 km/h (5-10 mph) 

and check the light indicating the differential 

block-ing. The light should be off when the 

switch is in the unlocked or disengaged position. 

4. Continue to drive the vehicle and place the 

switch of the differential blocking system in 

the locked or engaged position. Take your 

foot off the accelerator to remove the torque 

of the cardan shaft and allow the blocking position 

to be changed. The light should be on 

when the switch is in the locked position. 

• If the indication light continues to be ON with 

the switch in the unlocked position, the blocking 

system is still in the locked position. 

Check if the manual gearing screw has been 

removed from the cylinder cover of the drive 

mechanism of the differential blocking. See 

the o procedure in this section. 

Label of Driver Care with the 

DCDL Check if the driver care label is installed 

in the vehicle cabin. Figure 143. The label 

should be placed in a place easy to be seen by 

the driver. The recommended place is on the 

instrument panel, next to the indication lamp 

and differential locking switch. 

! 

CAREFUL 

This vehicle is equipped with a Shaft Blocking System, 

controlled by the driver. (DCDL) 

• Only use the DCDL in poor road conditions 

• Do not activate when descending 

• Do not activate the blocking in speeds above 40 Km/H 

W hen the blocking is activated, the vehicle may be uncomfortable 

to drive, which requires care in the procedure of operating 

the vehicle. When the blocking is deactivated, the driving 

conditions return to normal. 

For further information about using the blocking, see 

the vehicle operator’s manual 



The use of incorrect lubricants or those with 

unsuitable additives is, usually, the greatest 

cause of failures occurring in differentials. 

The lubricating oil specified for the differential 

must have features of extreme pressure (EP), 

service classification API-GL- 5 of the “American 

Petroleum Institute” and meet the requirements 

of the American military specification 

MILL-2105-C. 

This type of oil, better known as hypoid oil, has 

a lubricating film capable of supporting high 

work load pressure, which makes it appropriate 

for hypoid gears, where the lubrication condi- 

-tions are rather severe. 

Viscosity 

Generally speaking, the high viscosity degree 

of monoviscous oil is suited to high ambient 

temperatures. Besides extending the useful life 

of the gears, opting for a multiviscous oil will 

satisfy the temperature conditions found. The 

table below represents the viscosity selection 

of oils: 

MILITARY 

SPECIFIC. 

OIL DESCRIPTION 

MIN. 

AMBIENT TEMP. 

MAX. 

MIL - L2105 - C/D API GL-5 85W/140 -X- 

-12 C° 

MIL - L2105 - C/D API GL-5 80W/140 

-15 C° 

MIL - L2105 - C/D API GL-5 80W/140 

MIL - L2105 - C/D API GL-5 75W/140 

MIL - L2105 - C/D API GL-5 75W/140 

-28 C° 

-40 C° 

-40 C° 

MIL - L2105 - B API GL-5 90 

MIL - L2105 - B API GL-5 140 

0 C° 

+4 C° 

-X- 

-X- 

-X- 

-X- 

-X- 

-X- 


57

Lubrication 

Inspection and Recommendations 

Every 2000km check that the oil level is correct. 

Execute the drainage operation while the oil is 

still warm. This allows the lubricant to flow freely 

and more quickly, reducing the time required 

to drain the oil completely from the differential. 

Complete the level or resupply until the lubricant 

runs slightly over the lower edge of the oil 

level filling hole. 

The shaft should not be washed internally with 

any type of solvent (kerosene, gasoline, diesel 

oil, etc.). 

After each oil change, and before placing the 

vehicle in normal operation, drive limiting the 

speed to 40 km/h, for 5 to 10 minutes, or 2 to 3 

km to ensure that all the channels and pockets 

were duly filled with the lubricating oil. 

f the differential is a replacement unit, not foreseen 

for immediate reuse, all the bearings and 

gears should be covered with a good layer of 

anticorrosive oil. 

In this case, the differential should be maintained 

in a closed box until its reuse, to avoid 

contact between dust and other impuri-ties and 

the unit. 

Change the oil every 160,000 km or once a 

year, whichever occurs first. 

Vehicles which operate on the highway or off 

the road in severe applications, using the maximum 

load capacity allowed, should change the 

oil at intervals of 40000 - 50000 km, or every six 

months, whichever occurs first. 

Magnetic Plug 

MERITOR recommends using magnetic plugs 

in the oil drainage hole of the shaft. 

IMPORTANTE: 

The magnetic plug quickly loses its efficiency 

when it accumulates many metallic 

particles, and, therefore, should be cleaned 

before losing its efficiency. The removed 

plug can be cleaned and reused. It is advisable 

to practice this procedure once or 

many times within the period of changing 

the oil. 

Change Periods 

New or Reconditioned Units. In the initial period 

(running in), change the oil of the differential between 

2000 and 5000 km. This initial change is 

recommended to ensure the removal of metallic 

particles, usually released in a greater quantity 

during this phase. 

After the Running In Period Vehicles which 

operate basically on highways, with work loads 

below their maximum capacity of load allowed. 


Torque Table 

ITEM DESCRIPTION 

1 

2 

3 

4 

5 

6 

7 

8 

Pinion nut 

Screw (fastening pinion box) 

Screw (fastening satellite box) 

Filling hole and oil level 

Screw (fastening bearing) 

Nuts (fastening crow) 

Draining plug 

Breathing plug 

TORQUE SPECIFIED N.m (lbf.PÉ) 

RS 120 145/147 155 160 185 

1006-1250 (740-920) 

95-150 (70-110) 

129-156 (95-115) 

47 mín. (35 mín) 

245-299 (180-220) 

150-177 (110-130) 

47 mín (35 mín.) 

2,3 - 2,8 (20-25) 

1250-1535 (920-1130) 

95-150 (70-110) 

130-155 (95-115) 

47 mín. (35 mín.) 

430-540 (320-400) 

220-290 (160-210) 

47 mín. (35 mín.) 

2,3-2,8 (20-25) 

1250-1535 (920-1130) 

91-150 (67-91) 

235-290 (175-214) 

47 mín. (35 mín.) 

575-705 (425-520) 

300-365 (220-270) 

47 mín. (35 mín.) 

27 mín. (20 mín.) 

1350-1670 (1000-1230) 

95-150 (70-110) 

300-420 (220-310) 

47 mín. (35 mín.) 

650-810 (480-600) 

265-355 (195-262) 

47 mín. (35 mín.) 

27 mín. (20 mín.) 

1350-1670 (1000-1230) 

95-150 (70-110) 

300-420 (220-310) 

47 mín. (35 mín.) 

650-810 (480-600) 

365-355 (195-262) 

47 mín. (35 mín.) 

27 mín. (20 mín.) 


59

Always use Technical Manuals of... 

MAINTENANCE MANUAL

Always use original parts 

For more details, see the Spare Parts Catalog 

Customer service 

55 11 3684.6741 

55 11 3684.6867 

Purchase the CD-ROM failure analysis of components of the axis 

traction 

Customer Service 

Av. João Batista, 825 - Osasco - SP - 06097-105 

Tel. (11) 3684-664 - (11) 3684-6867 

AfterMarket (Replace parts) 

R. Ester Rombenso, 403 - Osasco - SP - 06097-120 

Tel. (11) 0800-555530 

www.arvinmeritor.com

MAINTENANCE MANUAL - Meritor

Create successful ePaper yourself

Delete template?

Save as template?