MAINTENANCE MANUAL - Meritor

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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. WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Note all warnings and cautions provided by the press manufacturer to avoid damage to components and serious personal injury. Installation Installing the Drive Pinion, Adjusting Pinion Depth and Preload Bearings There are two procedures for adjusting pinion depth. The procedure in this manual is to install the pinion, bearings and calculated shim pack into the case WITHOUT the helical gear and two spacers. After you check the tooth contact patterns to determine the correct pinion position, you must disassemble the differential to install the helical gear and two spacers. An optional procedure is to install the pinion, bearings and calculated shim pack into the case WITH the helical gear and two spacers. After you check the tooth contact patterns to determine the correct pinion position, you only need to disassemble the differential if an adjustment is necessary. Both procedures are acceptable. Adjustment Shim Pack Thickness for a New Drive Pinion NOTE: Use this procedure if you’ll install a new drive pinion and ring gear set or if you have to adjust the depth of the drive pinion. If the pinion depth shims are misplaced during differential repair, use 0.030 inch (0.76 mm) for 145 Series differential and 0.050 inch (1.27 mm) for 160 Series differential for the initial pinion position. Figure 5.1. MAINTENANCE MANUAL OUTER BEARING CONE HELICAL DRIVEN GEAR SPACER INNER BEAR- ING CUP Assembly and Installation OUTER BEARING CUP SPACER DRIVE PINON SHIMS INNER BEARING CONE Figure 5.1 1. Use a micrometer to measure the thickness of the shim pack that was removed from the differential differential. Record the measurement. Figure 5.2 Figure 5.2 2. Find the pinion cone (PC) variation number on the drive pinion you’ll replace. Record the number. Figure 5.3. • PC+3, PC-3, +3 ou -3 = 0.003” • PC +.03, PC 0.03 mm, +0.03 mm ou -0.03 = 0.03 mm. PINION CONE VARIATION NUMBER Figure 5.3 41
Assembly and Installation 3.If you can’t find the PC number or it’s unreadable, install a new shim pack of the same thickness that you measured in Step 1. NOTE: The following calculation is the opposite for a rear differential, forward tandem or single. 4. If the old pinion cone variation number of a front tandem differential is a plus (+), ADD the cone variation number to the old shim pack thickness that was measured in Step 1. 5. If the old pinion cone variation number of a front tandem differential is a minus (–), SUB- TRACT the cone variation number from the old shim pack thickness that was measured in Step 1. 6. Find the pinion cone variation number on the new drive pinion that will be installed. Record the number. 7. If the new pinion cone variation number of a front tandem differential is a plus (+), SUB- TRACT the variation number from the standard shim pack thickness that was calculated in Step 4 or Step 5. Use new shims to make a shim pack to the determined thickness. See Table F. 8. If the new pinion cone number of a forward tandem differential is a minus (–), ADD the number to the standard shim pack thickness that was calculated in Step 4 or Step 5. Use new shims to make a shim pack to the determined thickness. See Table F. TABLE F Drive Pinion Assembly The depth of the drive pinion and ring gear contact is controlled by the thickness of the shim pack. Figure 5.4. • To increase the thickness of the drive pinion contact, increase the thickness of the shim pack. • To decrease the depth of the drive pinion pattern, decrease the thickness of the shim pack. OUTER BEARING CONE Exemplos mm inches 1.Old Shim Pack Thickness Old variation PC =PC+2 Standard Shim Pack Thickness New variation PC=PC+5 New Shim Pack Thickness 1.Old Shim Pack Thickness Old variation PC=PC-2 Standard Shim Pack Thickness New variation PC=PC+5 New Shim Pack Thickness 1.Old Shim Pack Thickness Old variation PC=PC+2 Standard Shim Pack Thickness New variation PC =PC-5 New Shim Pack Thickness 1.Old Shim Pack Thickness Old variation PC=PC-2 Standard Shim Pack Thickness New variation PC=PC-5 New Shim Pack Thickness INNER BEARING CUP DRIVE PINO 0,780 +0,050 =0,810 -0,120 =0,690 0,780 +0,050 =0,710 -0,120 =0,590 0,780 +0,050 =0,810 -0,120 =0,930 0,780 +0,050 =0,710 -0,120 =0,830 0,030 +0,002 =0,032 -0,005 =0,027 0,030 +0,002 =0,028 -0,005 =0,023 0,030 +0,002 =0,032 -0,005 =0,037 0,030 +0,002 =0,028 -0,005 =0,033 OUTER BEARING CUP 42 MAINTENANCE MANUAL SHIMS INNER BEAR- ING CONE Figure 5.4
Page 1 and 2: MT 46-145 MT 50-168 MAINTENANCE MAN
Page 4 and 5: Notes About This Manual This manual
Page 6 and 7: Single Reduction Forward Differenti
Page 8 and 9: RIGHT. SIDE CURRENT DCDL NO SPIN®
Page 10 and 11: • When the collar splines engage
Page 12 and 13: Hazard Alert Messages Read and obse
Page 14 and 15: 5. Install a cover over the open en
Page 16 and 17: CAUTION WHEN USING A PRY BAR, BE CA
Page 18 and 19: 3. Press the output shaft through t
Page 20 and 21: A. Lift the input shaft assembly un
Page 22 and 23: 3. Remove the snap ring that fasten
Page 24 and 25: Removal Inter-Axle Differential Loc
Page 26 and 27: 7. Use an appropriate lifting devic
Page 28 and 29: 2. Remove the drive pinion from the
Page 30 and 31: Clean Ground and Polished Parts 1.
Page 32 and 33: CAUTION A THRUST WASHER, DIFFERENTI
Page 34 and 35: 9. For complete welding instruction
Page 36 and 37: CAUTION APPLY SILICONE GASkET MATER
Page 38 and 39: Hypoid Gear Set Ratios Listed on th
Page 40 and 41: • If the axle ratios shown on the
Page 44 and 45: The preload of the bearings on the
Page 46 and 47: SPACER- AVAILABLE IN DIFERENT SIZES
Page 48 and 49: 14. Use a press and a sleeve to pre
Page 50 and 51: 4. Measure the outer diameter of th
Page 52 and 53: 9. Apply axle oil lubricant on the
Page 54 and 55: Installation Case Halves and Ring G
Page 56 and 57: Adjustment Main Differential Case B
Page 58 and 59: 5.If the difference is at or within
Page 60 and 61: PART NUMBER Examples The following
Page 62 and 63: 5. Change the thickness of the shim
Page 64 and 65: 5.Tighten the jam nut, if equipped,
Page 66 and 67: A. Apply axle lubricant to the inne
Page 68 and 69: E. Install the input bearing cage o
Page 70 and 71: NOTE: The shim pack under the input
Page 72 and 73: 9. Inspect the clearance operation
Page 74 and 75: Inspection Adjust of the clearance
Page 76 and 77: 6. Position the installation tool a
Page 78 and 79: Tight Fit Forks and POSE Seal . 1.
Page 80 and 81: CAUTION USE A PRESS AND A SLEEVE OR
Page 82 and 83: 14. Adjust the shift fork for the i
Page 84 and 85: 5. If the axle shaft flange have cy
Page 86 and 87: Fill the Axle with Lubricant NOTE:
Page 88 and 89: Engagement or Lockout of the DCDL W
Page 90 and 91: Differential and Gear Assembly and
Page 92 and 93:
NOTE: Some models use silastic seal
Page 94 and 95:
10. Engage the splines of the colla
Page 96 and 97:
VERSIÓN FIJADA POR TORNILLOS SHIFT
Page 98 and 99:
5. Install the differential into th
Page 100 and 101:
MAINTENANCE MANUAL Lubrification Sp
Page 102 and 103:
Torque Specifications MAINTENANCE M
Page 104 and 105:
Tabela Q: General Torques Specifica
Page 106 and 107:
Table U: Drive Pinion Bearings —
Page 108 and 109:
Specifcations Mounting Bracket to D
Page 110 and 111:
Table AE: Unitized Pinion Seals and
Page 112 and 113:
7. Release conical washers, if used
Page 114 and 115:
8. Unlock or disengage the DCDL by
Page 116 and 117:
14. Lock or engaged the main differ
Page 118 and 119:
PARAFUSO CONICAL WASHER RETENTION S
Page 120:
Always use original parts For more
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MAINTENANCE MANUAL - Meritor

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