MAINTENANCE MANUAL - Meritor

Differential and Gear Assembly and
Main Differential Lock
Threaded DCDL Shift Assembly
The current design shift fork does not employ
roll pins. Nubs on the inner face of the fork hold
the shift collar in place. Figure 6.4.
1. Verify that the differential lock is released and
the engaging capscrew and seal are removed
from the shift cylinder.
2. Tap the shift collar with a rubber mallet to loosen
and remove the collar from the shift fork.
Figure 6.5.
SHIFT FORK
MAINTENANCE MANUAL
SHIFT COLLAR
Figure 6.5
3. Remove the differential lock sensor switch, if
used, and jam nut from the differential. Figure
6.6.
Figure 6.6
4. Remove the shift cylinder and piston assembly
from the differential by turning it to
the left. Figure 6.7.
Driver-Controlled Main Differential Lock
Figure 6.7
5. Place the shift cylinder and piston assembly
in a vise that has brass covers over the jaws.
Remove the piston and O-ring from inside the
cylinder. Use a narrow drift through the hole in
the top of the cylinder to push out the piston. It
may be necessary to use a mallet to tap out the
piston. Figure 6.8.
DRIFT
Figure 6.8
6. Carefully remove the O-ring from the piston.
Use a thin pointed tool to remove the O-ring.
Do not damage the piston. Figure 6.9.
Figure 6.9
7.Inspect the O-ring for any damage such as
cracks, cuts or breaks.
• If the O-ring is damaged, replace it with a new
O-ring when you assemble the components.
8.Clean and inspect all shift assembly parts.
See the Section 4.
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