Related Manuals for Meritor 3000 Series
Summary of Contents for Meritor 3000 Series
- Page 1 Issued 08-02 Differential Carriers 3000, 4000 and 5000 Series Maintenance Manual MM-02133...
- Page 2 Service Notes Before You Begin Access Product and Service Information Service Notes on Our Website This manual provides instructions for Meritor’s 3000, 4000 and 5000 Series differential carriers. Visit the DriveTrain Plus by ArvinMeritor Tech Before you begin procedures: Library at arvinmeritor.com to access and order product and service information.
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Page 3: Table Of Contents
Install Fasteners ..............10 New Fasteners with Pre-Applied Adhesive Original or Used Fasteners Using Meritor Liquid Adhesive 2297-C-7049 or ®... -
Page 4: Exploded View
Exploded View Exploded View 14 13 Item Description Item Description Item Description Differential Assembly Differential Shim Shift Collar Carrier Housing Tapered Bearing Shift Fork Retaining Ring Differential Cap Large Pinion Shim Shift Fork Capscrew Small Pinion Shim Shift Fork Retainers Adjusting Nut Tapered Bearing Shift Fork Pin... -
Page 5: Section 1: Introduction
Section 1 Introduction This manual provides service information for Meritor‘s 3000, 4000 and 5000 Series carrier assembly with the differential lock feature. Figure 1.1 . To identify the axle, refer to the identification plate on the front of the beam. -
Page 6: Section 2: Removal
Section 2 Removal Section 2 Removal Figure 2.1 WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. -
Page 7: Differential Lock Assembly
Section 2 Removal Figure 2.4 Figure 2.7 Differential Lock Assembly Figure 2.8 1. Remove the shift collar retaining ring. Remove the shift collar. Figures 2.5 and 2.6 . Figure 2.5 Figure 2.9 Figure 2.6 3. Hold the input flange with the pin wrench and loosen the flange nut. -
Page 8: Differential Assembly From The Carrier
Section 2 Removal Figure 2.10 CAUTION When you remove fasteners secured with adhesive, slowly heat the fastener to 350°F (177°C). Do not exceed this temperature, or heat fasteners quickly. Damage to components can result. 2. Remove the differential caps capscrews and differential caps. -
Page 9: Bevel Pinion Assembly
Section 2 Removal Bevel Pinion Assembly 1. Remove the bevel pinion, oil seal and shim from the housing. Figure 2.15. 2. Use a puller to remove the bearing cone from the bevel pinion. Figure 2.16. 3. Remove the bearing cups from the housing. Figure 2.17. -
Page 10: Section 3: Prepare Parts For Assembly
Section 3 Prepare Parts for Assembly Clean Rough Parts Section 3 Prepare Parts for Assembly WARNING 1. Clean rough parts with the same method as To prevent serious eye injury, always wear safe cleaning ground and polished parts. eye protection when you perform vehicle 2. -
Page 11: Inspect Parts
Section 3 Prepare Parts for Assembly Inspect Parts Figure 3.2 It is very important to inspect all parts carefully and completely before the axle or carrier is assembled. Check all parts for wear and replace damaged parts. 1. Inspect the cup, cone, rollers and cage of all tapered roller bearings in the assembly. -
Page 12: Repair Or Replace Parts
Always replace a damaged drive axle housing. Do Repair or Replace Parts not bend or straighten a damaged housing, which can misalign or weaken it, and void Meritor’s warranty. NOTE: Threads must be without damage and clean so that accurate adjustments and correct torque Removing Fasteners Secured with values can be applied to fasteners and parts. -
Page 13: Install Fasteners
NOTE: The following silicone gasket products or adhesive from all threads and threaded holes. equivalent can be used for Meritor components: Three Bond Liquid Gasket number TB 1216 NOTE: Apply four or five drops of Meritor liquid (Grey) ® adhesive, Loctite 680 adhesive, or equivalent, inside each threaded hole or bore. - Page 14 Section 3 Prepare Parts for Assembly Figure 3.8 Remove old sealant material. HOUSING AND CARRIER SHOWN Remove old sealant material. Housing and Carrier Shown CAUTION Apply silicone gasket material in a continuous 1/8-inch (3 mm) bead. If you use more than this amount, the gasket material can break off and plug lubrication passages.
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Page 15: Section 4: Installation
Section 4 Installation Section 4 Installation WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance and service. Installation NOTE: Refer to Section 6 for drawings to build the tools used in the following procedures. Bevel Pinion Assembly 1. - Page 16 3. Use the appropriate tool to install the large Figure 4.4 pinion adjusting shim and the inner bearing cup into the housing. Figure 4.2. 3000 Series: Use tool number 5008. 4000 and 5000 Series: Use tool number 5023. Figure 4.2 6.
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Page 17: Differential Assembly Into The Carrier
10. Install the flange and tighten the nut. Figure 4.7. 1. Use the appropriate tool to install the bearing 3000 Series: 405-434 lb-ft (549-589 N•m) cones on the differential assembly. Figure 4.9. 4000 and 5000 Series: 543-572 lb-ft 3000 Series: Use tool number 5010. -
Page 18: Check The Ring Gear Backlash
4000 123-137 (170-186) 0.0137-0.017 (0.35-0.45) Backlash/Inch (mm) 5000 123-137 (170-186) 0.0137-0.017 (0.35-0.45) 3000 Series 7 x 35 through 22 x 35 0.007-0.009 (0.18-0.23) 11 x 27 through 20 x 27 0.0078-0.011 (0.20-0.28) Figure 4.10 4000 Series 11 x 27 through 15 x 27 0.012-0.016 (0.30-0.41) - Page 19 Section 4 Installation Figure 4.13 Figure 4.14 1001092a Good Hand-Rolled Pattern 2. Rotate the ring gear forward and backward so that the 12 gear teeth go past the drive pinion six times to get the contact patterns. Repeat if Figure 4.15 needed to get a clearer pattern.
- Page 20 Section 4 Installation Figure 4.17 Figure 4.19 Good Pattern in Operation Remove Adjustment Shims 4. Adjust the shims as necessary to move the 5. Adjust the backlash of the ring gear within contact patterns between the top and bottom the specification range to move the contact of the gear teeth.
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Page 21: Oil Seal
Oil Seal 1. Remove the flange. Use the appropriate tool to install the seal. Figures 4.22 and 4.23. 3000 Series: Use tool number 5009. 4000 and 5000 Series: Use tool number 5088. 2. Position the flange. Tighten the nut to specification. - Page 22 Section 4 Installation Figure 4.26 Figure 4.29 2. Install the two shift fork retainers. Position the Figure 4.30 shift collar. Figures 4.27 and 4.28. 3. Install the shift collar retaining ring. Position the differential lock cylinder. Figures 4.29 and 4.30. 4.
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Page 23: Differential Carrier Into The Axle Housing
Section 4 Installation 8. Stack the appropriate shims onto the screw Figure 4.32 between the differential lock cylinder face and the underside of the screw head. Figure 4.35. 9. Verify that play between the teeth is 0.004-0.020-inch (0.10-0.50 mm). 10. Remove the two screws from differential lock cylinder. -
Page 24: Differential Lock Cylinder
Section 4 Installation Series Screws Nuts lb-ft (N•m) Figure 4.36 3000 12 x 150 83-91 (113-123) 4000 14 x 150 140-152 (195-210) 5000 14 x 150 Figure 4.38 Figure 4.37 Figure 4.39 3. If you are using taper rings, coat the contact face of the three taper rings with silicone gasket material and install the rings. - Page 25 Section 4 Installation 3. Tighten the screws to 22-32 lb-ft (30-45 N•m). Connect the air pressure line and the switch wires. Figure 4.40. Figure 4.40 Copyright 2002 Maintenance Manual MM-02133 Page 22 ArvinMeritor, Inc. Issued 08-02...
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Page 26: Section 5: Lubrication
filled for the fluids to flow through the Lubricant Quality complete assembly. Depending on operating conditions, Meritor 3. Loosen the plug in the top or a fastening recommends a multigrade lubricant 80 W 90 with screw to permit air to be removed. -
Page 27: Series 3000
Section 6 Special Tools Series 3000 Section 6 Special Tools Drive Block 5007 Figure 6.1 45° 160 ± 1 Ø 38.5 Ø 51 Ø 62 Drive Block 5008 Figure 6.2 Ø A –0.5 +0.2 14 +0.1 30° 2 ± 0.1 Bearing 5008-2 32310B... - Page 28 Section 6 Special Tools Drive Block 5009 Figure 6.3 Knurled 2 x 2 30° Ø 30 15° 3 x 3 Drive Block 5010 Figure 6.4 R = 05 R = 2 to 3 Ch 2 x 2 Bearing 30 ± 1 5010-1 32010X 5010-2...
- Page 29 Section 6 Special Tools Flange 5012 Figure 6.5 Nut welded Ø 14 ± 0.2 Ø 14 ± 0.2 15.5 15.5 Drive Block Handle 5005 Figure 6.6 30° Ø 25 –0.1 Ø 14 –0.2 2 x 2 Ø 2 ± 0.1 14 ±...
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Page 30: Series 4000 And 5000
Section 6 Special Tools Series 4000 and 5000 Drive Block 5023 Figure 6.7 Ø X +0,1 Ø 20.1 –0 Bearing 5023-1 32312B 5023-2 32310B 20° Ch 2 x 2 Ø Y Drive Block 5027 Figure 6.8 BEARING 32310 BEARING 32312B Ø... - Page 31 Section 6 Special Tools Drive Block 5030 Figure 6.9 Ø 30 ± 0.4 2 x 2 Knurled Bearing 5030-1 32015X 5030-2 32016X R = 5 1 x 1 Ø A ± 0.2 Ø B ± 0.2 Drive Block 5088 Figure 6.10 Knurled Ø...
- Page 32 Section 6 Special Tools Flange 5020 Figure 6.11 M16 x 150 Ø 18 Nb = 2 Nb = 1 264.6 Drive Block Handle 5021 Figure 6.12 Ch 2 x 2 30° –0.1 Ø 30 Ø 20 –0.2 Knurled Ø 5 22 ±...
- Page 33 Information contained in this publication was in effect at the time the publication was approved for printing and is 2135 West Maple Road subject to change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the Troy, MI 48084 USA information presented or discontinue the production of parts described at any time.