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Meritor RS 120 Field Maintenance Manual

Single reduction axle
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SINGLE REDUCTION AXLE
RS 120 - Rear Axle
FIELD MAINTENANCE MANUAL
_________________________________________________
Meritor HVS (India) Limited,
Plot No: 36, Hootagalli Industrial Area,
Off Hunsur Road, Mysore-570 018
Ph: +91 821 2403235 Fax: +91 821 2403234
Phone: +91 821 2403235 fascimile:+91 8212403234

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  • Page 1 SINGLE REDUCTION AXLE RS 120 - Rear Axle FIELD MAINTENANCE MANUAL _________________________________________________ Meritor HVS (India) Limited, Plot No: 36, Hootagalli Industrial Area, Off Hunsur Road, Mysore-570 018 Ph: +91 821 2403235 Fax: +91 821 2403234 Phone: +91 821 2403235 fascimile:+91 8212403234...

  • Page 2: Table Of Contents

    Disassemble Main Differential Case and Ring Gear Assembly ..........06 Removal and Disassemble Drive Pinion Assembly ..............10 3. GENERAL INFORMATION Dri-Loc Fasteners, Meritor Liquid Adhesive and Loctite 277 ..........13 Application of Silicone Gasket Material ..................14 4. PREPARE PARTS FOR ASSEMBLY Clean Ground and Polished Parts.....................18 Inspect Parts...............................19...

  • Page 3: Introduction

    Introduction Standard Single-Reduction Carriers Meritor single-reduction standard carriers, Figure Below, are used in most Meritor single axles, rear of tandem axles and front drive steering axles. The single-reduction carrier models are front mounted into the axle housing. These carriers have a hypoid drive pinion and ring gear set and bevel gears in the differential assembly.

  • Page 4: Disassembly

    Disassembly REMOVAL OF DIFFERENTIAL CARRIER FROM AXLE HOUSING: 1. Raise the rear end of the vehicle put on jack stands Figure1. Jack Stands Figure 1 2. Disconnect the propeller shaft from input flange. Figure 2. remote drain plug and drain differential oil.

  • Page 5: Removal Main Differential Case And Ring Gear Assembly

    Disassembly Figure 3 3. Use tool (A) to stop rotation of wheel end assembly and undo screws (B) fastening axle drive shaft to wheel hub. Figure 3. • Remove axle shafts using extraction holes. • Remove all the carrier mounting fasteners.

  • Page 6: Disassemble Main Differential Case And Ring Gear Assembly

    Disassembly II DISASSEMBLY OF DIFFERENTIAL • If the same gear set is to be reused record the backlash before disassembly. Figure 5. Figure 5 Bearing Cap Carrier Leg 1. Make match marks on one Carrier leg and bearing cap. Figure 6 Match Marks Figure 6...
  • Page 7 Disassembly Remove cotter pin using a small drift and hammer. Figure 7. Removing Cotter Key Figure 7 • Remove cap screw, washers and lock plate. Figure 8. Figure 8...
  • Page 8 Disassembly 4. Remove cap screws and washers of bearing caps. Figure 9. • Remove bearing adjusting Bearing rings Figure 9 Figure 10 5. Lift the differential case & ring gear assembly Figure 10.
  • Page 9 Disassembly 6. Make match makes on the diff. case halves. Figure 11. Match Marks Match Marks Figure 11 Trust Washer Side 7. Remove the diff. case bolts. Gear separate case halves. Remove spider, pinions, side gears and thrust washers. Figure 12. Figure 12...

  • Page 10: Removal And Disassemble Drive Pinion Assembly

    Disassembly 8. Remove the ring gear Press bolts and nuts. Case Half Plate • Remove the ring gear from diff.case using a press Figure 13. Figure 13 Puller 9. Remove the bearings from diff. cases using bearing Press puller/press Figure 14. Figure 14 10.
  • Page 11 Disassembly 11. Remove the companion flange DRIVE PINION AND BEAR ING CAGE using a suitable puller, Figure 16. • Remove cap screws and washers of bearing Cage, SHIMS • Remove bearing Cage and shims • Measure and note down the total thickness of Figure 16 removed shims.
  • Page 12 Disassembly 13. Remove the oil seal. figure18 • Take out the outer bearing Pinion cone. • Remove the bearing cups from the cage using a small drift and Bearing cage hammer. Figure 18 Drive Pinion Inner Bearing Cone Bearing 14. Remove the inner bearing cone using the split puller and press.Figure 19.

  • Page 13: General Information

    Tighten the Dri-Loc fasteners to the required torque value for that size 2. Apply four or five drops of Meritor fastener. There is no special procedure Liquid Adhesive or Loctite 277 to the or torque value required. See the torque threaded holes ONLY.

  • Page 14: Application Of Silicone Gasket Material

    Meritor fastener. See the torque chart The components. fastener MUST NOT rotate. 1. General Electric No. RTV-1473 black. 2. If the fastener rotates any amount, remove fastener from the 2.
  • Page 15 General Information Remove all old gasket material CAUTION: from both surfaces. amount silicone gasket material applied must not exceed Clean the surfaces where silicone a.125 Inch diameter bead. Too much gasket material will be applied. gasket material can block lubrication Remove all oil, grease, dirt and passages.
  • Page 16 The location of the marks are shown in Figure 23. 3. Gear Set Match Number: Part Number: Meritor drive pinions and ring gears are Examples of gear set part available only as matched sets. Both numbers: Ring gear – A–2–...
  • Page 17 General Information 4. Pinion Cone Variation Number: NOTE: The pinion cone variation number is not used when checking for a matched gear set. The number is used when you adjust the depth of the pinion In the carrier. See the procedure for adjusting the shim pack thickness under the pinion cage. Examples of pinion cone variation numbers: PC+3, PC-5, +2, -1, +.01 mm or - 0.02mm Location on Gear Set: End of pinion gear head or outer diameter of ring gear.

  • Page 18: Prepare Parts For Assembly

    Prepare Parts for Assembly Clean Ground and Polished Clean Rough Parts Parts 1. Clean rough parts the same as cleaning ground and polished parts. 1. Use a cleaning solvent to clean ground or polished parts or surfaces. 2. Rough parts can be cleaned in hot Kerosene or diesel fuel oil can be solution tanks with a weak alkaline used for this purpose.

  • Page 19: Inspect Parts

    Prepare Parts for Assembly Figure 25 Inspect Parts It is very important to inspect all parts carefully and completely before the axle WEAR or carrier is assembled. Check all parts CRACK GROOVE for wear or stress and replace damaged parts. Replacement of damaged parts now, will prevent complete failure of the assembly later.
  • Page 20 Prepare Parts for Assembly Figure 28 ETCHING & PITTING CAUTION: Hypoid drive pinions and ring gears are machined in a matched set. When a drive pinion or ring gear of a hypoid gear set needs to be replaced, both gears must be replaced at the same time.

  • Page 21: Repair Or Replace Parts

    1. Replace any fastener if corners of the Repair Axle By Welding head are worn. 2. Replace washers if damaged. 1. Meritor Automotive, Inc. will permit 3. Replace gaskets, oil seals or grease repairing drive axle assemblies by seals at the time of axle or carrier welding ONLY in the following areas: repair.
  • Page 22 G. Use a 70,000 psi tensile weld welding at locations other than the material and the correct voltage and three areas permitted by Meritor will amperage for the diameter weld rod make the heat-treated component used. Examples of weld rod that can weak.
  • Page 23 6. Fill the axle assembly with the 3. The opening in seam welds MUST be correct amount of lubricant. See ground out to 70% of the wall Meritor Maintenance Manual for thickness. The wall thickness can be information on lubricants. measured at the carrier opening of housing.

  • Page 24: Assembly

    Assembly IV ASSEMBLY OF CARRIER • Before installing a new gear set ensure the set number etched on the ring gear and drive pinion are same • Location of marks are as shown in Figure 30. A> Tooth combination number A.
  • Page 25 Assembly Inner Sleeve Bearing Cone 2. Press the inner bearing cone on the pinion till it sits firmly. Figure 32. Figure 32 Figure 33 3. Press the spigot bearing Press on the drive pinion Figure 33. Sleeve Spigot Bearing...
  • Page 26 Assembly 4. Install the snap ring into the groove. Snap Ring Spigot brg Figure 34. Figure 34 Outer Bearing Bearing Cone Spacer 5. Position the bearing cage over inner bearing cone. • Apply axle lubricant on bearings. • Install the bearing spacer. •...
  • Page 27 Assembly 6. Check. and correct the preload of Press Pressure pinion bearings. adopting following procedure. Sleeve Place the pinion cage assy. in a press. Install a sleeve on outer bearing. Figure 36 Apply 30,000 lbs (15 tons) pressure. While pressure is held, wind a cord around the cage with the spring scale.
  • Page 28 Assembly 7. Apply grease to the oil Seal Seal lips and the cavity Driver between lips. • Use a mallet and the sleeve to install the seal. Figure 37. 8. If new gear set is installed adopt the following procedure to arrive at correct mounting distance of drive pinion.

  • Page 29: Adjust Thickness Of Shim Pack For Hypoid Pinion

    Assembly Calculation of Shim pack thickness for Hypoid Pinion Example Inches 1. Old Shim Pack Thickness 0.030 0.760 Old PC Number, PC + 2 - 0.002 - 0.050 Standard Shim Pack Thickness = 0.028 = 0.710 New PC Number, PC + 5 + 0.005 + 0.130 New Shim Pack Thickness...

  • Page 30: Assemble Main Differential And Ring Gear

    Assembly 9. Install bearing cage assy. with the Figure 38 new shim pack calculated as above. Ring Gear Flange Case • Tighten bearing cage mounting bolts Half to the torque of 75 - 90 ft-Lb 10. Heat the ring gear in a water/ oil bath to about :l70⁰f(80⁰c) for 15 minutes.

  • Page 31: Check Rotating Resistance Of Differential Gears

    Assembly Figure 40 15. Check the rotating resistance of diff. gears Figure 40. √ Recommended torque is 5-20 ft.lbs. √ If torque is more, check case halves, spider, diff. gears, thrust washers. Replace the parts as necessary. Read Torque value Bearing Cap Adhesive Carrier...

  • Page 32: Install Differential And Ring Gear Assembly

    Assembly 17. Install diff. assy. into the carrier. Figure 42 Adjusting Ring √ Install both side adj. rings and hand tighten till these touches the diff. bearing .Figure 42. 18. Install the bearing caps aligning the match marks. figure.43 Bearing √...

  • Page 33: Adjust Preload Of Differential Bearings

    Assembly 19. Attach a dial. Indicator so DIAL INIDICATOR that that the plunger is against the back face of the ring gear. Figure 44. Figure 44 Pry bar Must Not Touch Bearings 20. Move the differential to the left and right with pry bars and ensure small amount of end play Figure 45.

  • Page 34: Check Run Out Of Ring Gear

    Assembly 21. Tighten the adj .ring opposite to ring “T” Bar Wrench gear till the indicator shows zero end play. Figure 46. 22. Tighten both adjusting. ring one notch to preload the diff. bearings. Adjusting Ring opposite Ring Gear Figure 46 23.

  • Page 35: Adjust Backlash Of Ring Gear

    Assembly 24. Position the dial indicator so that the plunger is on the drive side of the tooth. Figure 48. √ Adjust the backlash by loosening the one of the adjusting. ring and tightening the other adjusting. ring the equal amount Figure 48 BACKLASH SPECIFICATION: -BACKLASH RANGE = 0.008"...

  • Page 36: Check Tooth Contact Pattern Of Ring Gear Set

    Assembly 25. To increase backlash move the ring Figure 49 Tighten Adjusting gear away from the drive pinion. Figure Ring this side Increase Backlash Loosen Adjusting Ring this side Figure 50 26. To decrease backlash move the ring Loosen Adjusting Ring this side gear towards the drive pinion.
  • Page 37 Assembly 28. Compare the contact pattern to Figures.49,50 & 51. √ Good contact pattern - towards the toe of the gear teeth and in centre between top and bottom of teeth Figure 52. Figure 52 √ High pattern - this indicates that the drive pinion is not installed deep enough into the carrier.

  • Page 38: Adjust Preload Of Pinion Bearings

    Assembly 29. To correct the pattern proceed as follows. • High pattern- decrease the thickness Decrease Increase shim of shim pack under bearing cage. shim pack pack this will move the pinion towards ring gear. Figure 55. Figure 56 • Low pattern - increase the thickness Figure 55 of shim pack under bearing cage.
  • Page 39 Assembly Cotter 31. Torque tighten the bearing cap bolts to the value of 160-190 ft.lbs. Lock Plate Threaded Holes in Cap when Lock Plate is used 32. Install the cotter pin in the adj. ring using a drift and hammer. Figure 59. √...

  • Page 40: Install Differential Carrier Into Housing

    Assembly 33. Apply silicon gasket to the mounting surface of the housing. Figure 60. √ Carefully push the carrier into the position. Tighten the fasteners to the torque of 75-90 ft lbs. 1/8”(3.2mm) DIA. Silicon Gasket Figure 60 Cap screw or Stud Nut 34.

  • Page 41: Lubrication

    Section 13 Lubrication Lubrication Oil Capacity Recommended lubrication Oil capacity 6.5 liters (Guidelines only) Note: However, oil has to be filled up to filler plug level. Lubrication schedule for new and reconditioned units: First lubrication change: must be made at 1600-4800 Kms Subsequent lubricant change: must be made at every 40,000 to 48,000 Kms, when yearly mileage exceeds 96,000 Kms.
  • Page 42 Section 13 Lubrication Brake Assembly • Recommended lubricant Multi purpose chassis Grease Indian oil Servo grease MP Indian oil Servo Molex grease • Recommended greasing frequency once in 10,000 km • Greasing points (through nipple) camshaft bracket Assembly Rear spider assembly Note: To be greased till The grease flows from seal Plummer block.

  • Page 43: Fastener Torque Chart

    Fastener Torque Chart Torque Specifications: Fasteners Chart Fasteners Thread Size Ib-ft 0.31-24 18-24 24-33 1.Axle Shaft 0.50-13 85-115 115-156 Capscrew Plain Nut 0.44-20 50-75 68-102 0.50-20 75-115 102-156 0.56-18 110-165 149-224 2.Axle Shaft Stud Locknut V- 0.44-20 40-65 54-88 0.56-18 100-145 136-197 0.62-18...
  • Page 44 Fastener Torque Chart Fasteners Thread Size Ib-ft 3. Breather 0.38-18 20 minimum 27 minimum 4. Housing Oil Fill Plug 0.75-14 35 minimum 47.5 minimum 5. Heat Indicator Plug 0.50-14 25 minimum 34 minimum 6. Oil Drain Plug 0.50-14 25 minimum 34 minimum M12 x 1.75, Grade 7.

  • Page 45: Adjustment And Specification

    Adjustment and Specification Drive Pinion Bearings - Preload Specification: New bearings - 5-25 Ib-in torque. Used bearings in good condition - 5-15 Ib-in torque. Adjustment: Preload is controlled by the thickness of the spacer between the inner and the outer bearing. Drive Pinion - Depth in Carrier Specification: Install correct amount of shims between the pinion cage and the...
  • Page 46 Adjustment and Specification Ring Gear - Backlash Specification : Range of Backlash Setting :- .008 - .018 inch (.20 - .46 Adjustment: Backlash is controlled by the position of the ring gear. Change the backlash within specifications to get a good tooth contact pattern.

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