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Meritor RS 120 Maintenance Manual

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SINGLE REDUCTION AXLE
RS 120 - Rear Axle (NGIT)
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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Summary of Contents for Meritor RS 120

  • Page 1 SINGLE REDUCTION AXLE RS 120 - Rear Axle (NGIT) 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 3 Section 1 Introduction...

  • Page 4: Section 2 Disassembly

    Section 2 Disassembly REMOVAL OF DIFFERENTIAL CARRIER FROM AXLE HOUSING: Raise the rear end of the vehicle put on jack stands Figure1 Jack Stands Figure 1 Disconnect the propeller Shaft from input flange. Figure 2. remove drain plug and drain differential oil.
  • Page 5 Section 2 Disassembly Figure 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 Section 2 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 Section 2 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 Section 2 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 Section 2 Disassembly 6. Make match marks on the diff. case halves. Figure 11. Match Marks Match Marks Figure 11 Trust Washer Side Gear 7. Remove the diff. case bolts. separate case halves. Remove spider, pinions, side gears and thrust washers. Figure 12. Figure 12...
  • Page 10 Section 2 Disassembly 8. Remove the ring gear Press bolts and nuts. Plate Case Half • 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.
  • Page 11 Section 2 Disassembly DRIVE PINION AND Remove the companion flange BEARING 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 Section 2 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.

  • Page 13: Section 3 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 NOTE: 1. Apply the MINIMUM amount of The following silicone gasket torque required for that size products can be used on Meritor fastener. See the torque chart The components. fastener MUST NOT rotate. 1. General Electric No. RTV-1473 black.
  • Page 15 Section 3 General Information !CAUTION: Remove all old gasket material from both surfaces. The amount of 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 available only as matched sets. Both Examples of gear set part gears of a set have the same match numbers: Ring gear –...
  • Page 17 Section 3 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.
  • Page 18 Section 4 Prepare Parts for Assembly Clean Ground 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 Section 4 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.
  • Page 20 Section 4 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 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 correct amount of lubricant. See 3. The opening in seam welds MUST be Meritor Maintenance Manual for ground out to 70% of the wall information on lubricants. thickness. The wall thickness can be measured at the carrier opening of housing.

  • Page 24: Section 5 Assembly

    Section 5 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 Section 5 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 Section 5 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. Press the outer bearings cone on Bearing the pinion till it sits firmly on the...
  • Page 27 Section 5 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 Section 5 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 Section 5 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 Section 5 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 Section 5 Assembly 15. Check the rotating resistance of diff. Figure 40 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 Section 5 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 Section 5 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 Section 5 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 Section 5 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:...
  • Page 36 Section 5 Assembly 25. To increase backlash move the ring Figure 49 gear away from the drive pinion. Figure Tighten Adjusting 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 Section 5 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 Section 5 Assembly 29. To correct the pattern proceed as follows. High pattern- decrease the thickness Decrease Increase shim of shim pack underbearing 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 Section 5 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 Section 5 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: Lubricant Capacity

    Section 6 Lubrication LUBRICATION : SUMP 7.2 to 7.5 LITRES LUBRICANT CAPACITY Customer Scope Note: How ever oil has to be filled upto filler plug level LUBRICATION SCHEDULE FOR NEW AND RECONDITIONED UNITS; FIRST LUBRICANT CHANGE ------ AT 1600 - 4800 KMS. SUBSEQUENT CHANGES ------ ONCE IN 80000 KMS.

  • Page 42: Recommended Lubricants

    Section 6 Lubrication √ THERE IS NO UPPER LIMIT ON OUTSIDE TEMPERATURE. √ MAX. ALLOWABLE AXLE SUMP TEMPERATURE IS 121⁰C √ USE OF SAE 140 LUBRICANT WILL GIVE LONGER HYPOID GEAR LIFE, RECOMMENDED LUBRICANTS 1. GULF GEAR DB DURA MAX 85W140...

  • Page 43: Bill Of Material

    Section 7 Exploded View BILL OF MATERIAL ITEM PART NAME Housing Assy Carrier Assy., Axle shaft Finish Filler plug Drain Plug Washer –Hardened Bolt drive head to housing Stud drive head to housing Name plate Magnet...

  • Page 44: Section 7 Exploded View

    Section 7 Exploded View...
  • Page 45 Section 7 Exploded View...
  • Page 46 Section 7 Exploded View...
  • Page 47 Section 7 Exploded View...
  • Page 48 Section 7 Exploded View ILL No . Description ILL No . Description Brake shoe ( W/O Liner and roller) Spider Brake Brake shoe Lining Assy. Fitting Grease Spider Bushing Anchor pin Dust shield Top & bottom Anchor pin - Brake shoe Plug -Dust shield Spring - BRK Shoe Retaining Cap screw - Dust shield...

  • Page 50: Section 8 Fastener Torque Chart

    Section 8 Fastener Torque Chart Fasteners Thread Size Lb-Ft Breather 0.38-18 20Minimum 27Minimum Housing Oil Fill plug 0.75-14 35Minimum 47.5Minimum Heat Indicator Plug 0.50-14 25Minimum 34Minimum Oil Drain Plug 0.75 - 14 35Minimum 47Minimum M12 X 1.75 , Grade 12.9 Standard Differential Case to CAP Screw 105-125 143-169...
  • Page 51 Section 9 Adjustment and Specification...
  • Page 52 Section 9 Adjustment and Specification...
  • Page 54 Section 10 Disassembly of Brakes 11. Pullout the shaft from Figure 72 spider.Figure73. Figure 73  Remove the anchor springs and brake shoes. 12. Take out the dust shields by removing the mounting bolts. 10. Remove the lock ring washers and slack adjuster from cam shaft.
  • Page 55 Section 11 Cleaning and Inspection of Parts Cleaning Of Parts Figure74b  Use a cleaning solvent, kerosene or diesel. Dry the parts immediately after  cleaning. Coat all the parts with lubricant  to prevent corrosion and rust. Inspection And Replacement Of Parts.
  • Page 56 Section 12 Assembly of Brakes 1. Install the spider mounting Bolts & nuts. Figure 76 Tighten to the torque of 180-200 ft.lbs.Figure.75 Figure 75  If it exceeds 0.80 mm replace the bushes. Figure 77. Figure 77 2. Install the camshaft bracket in the spider with the new gasket.
  • Page 57 Section 12 Assembly of Brakes  Replacing the linings when found worn to the level of wear indication (built in the side wall of the linings at 4.5 mm thickness) 8. During relining make sure the contact surface of shoe and lining Seal Lip Seal Lip are clean.
  • Page 58 Section 12 Assembly of Brakes  10. Smear grease on all the slots of the Pull the shoes away from the Cam shoes. head and install the Rollers with retainers. Squeeze the ears of the Retainers so   Position the top shoe over the that the Retainers fit between the anchor pin.
  • Page 59 Section 12 Assembly of Brakes 15. Next to slack adjuster add Spacer Figure 87 washers 0.8 mm,1.4 mm, and 2.5 mm (hardened).  Ensure 2.5 mm (hardened) washer is next to lock ring. (hardened washer can be identified with the semi- circle groove on the i.d) Install a new lock ring.

  • Page 60: Section 13 Brake Adjustment

    Section 13 Brake Adjustment 1. Re-fix the drum and mount the B =………………. wheels. 2. Turn the adjusting nut of the slack adjuster till the lining touches. 3. Turn the adjusting nut in the opposite direction for one or two clicks so that the lining just clears the drum.
  • Page 61 Section 14 Major and Minor inspection of Brake Assy. Recommended Major and Minor Inspections: Minor inspection (during every lubrication schedule).  Spider mounting bolts.  Complete retraction of return springs.  Left over lining thickness. Major inspection (During every Re-lining ) Brakes spider for distortion and loose mounting bolts.