Meritor RS-220 Maintenance Manual
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Meritor RS-220 Maintenance Manual

Two-speed differentials
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Issued 04-01
$2.50
Two-Speed Differentials
RS-220/RS-230/RS-240
Maintenance Manual MM-0144

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Summary of Contents for Meritor RS-220

  • Page 1 Issued 04-01 $2.50 Two-Speed Differentials RS-220/RS-230/RS-240 Maintenance Manual MM-0144...
  • Page 2 Access Information on Service Notes ArvinMeritor’s Web Site This manual provides instructions for Meritor’s two-speed differential models RS-220, RS-230 and Additional maintenance and service information RS-240. Before you begin procedures: for ArvinMeritor’s commercial vehicle systems component lineup is also available at 1.

  • Page 3: Table Of Contents

    Table of Contents Exploded View ................1 Section 1: Introduction Introduction .
  • Page 4 Exploded View Exploded View...

  • Page 5: Exploded View

    Exploded View...

  • Page 6: Section 1: Introduction

    Section 1 Introduction Introduction Section 1 Introduction Figure 1.1 Welding on an Axle For complete welding instructions, refer to Maintenance Manual 8, Drive Axle Housings . Call ArvinMeritor’s Customer Service Center at 800-535-5560 to order this publication. Models RS-15-220 RS-17-220 and 224 RS-19-220 and 224 RS-21-230 Second Gear Ratio —...

  • Page 7: Section 2: Disassembly

    Section 2 Disassembly Section 2 Disassembly Brass Drift Method WARNING WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle Do not strike the round driving lugs on the flange maintenance or service. of an axle shaft. Pieces can break off and cause serious personal injury.
  • Page 8 Section 2 Disassembly 4. Remove the tapered dowels and separate the Air Hammer Vibration Method axle shafts from the main axle hub assembly. Figures 2.3 and 2.4 . CAUTION 5. Install a cover over the open end of each axle Do not use a chisel or wedge to loosen the axle assembly hub where an axle shaft was shaft and tapered dowels.
  • Page 9 Section 2 Disassembly Disassemble the Gear Shift Mechanism Remove the Carrier from the Axle 1. Manually remove the gear shift mechanism NOTE: Disassembly may be tight because of (in the opposite direction to the differential) residual tension in the gear shift mechanism. until it is in the low speed position (LS).
  • Page 10 Section 2 Disassembly A carrier stand, part number J 3409-D, is available from SPX Kent-Moore, 28635 Mound Road, Warren, MI 48092-3499. Figure 2.10 PLATES 8’ LONG x 3/4" THICK x 1-1/4" WIDE WITH A TONGUE TO FIT SLOT IN BAR WELD PLATES TO BAR HANDLE 7"...
  • Page 11 Section 2 Disassembly Remove the Differential and Ring Gear CAUTION from the Carrier Do not strike the plate directly or insert wedges or chisels between the plate and the differential WARNING carrier. Damage to components can result. Use a brass or leather mallet for assembly and Figure 2.13.
  • Page 12 Section 2 Disassembly 6. Clean oil from the ring gear and pinion teeth. Figure 2.17 Dry the parts immediately. Refer to Section 3 for procedures 7. Measure and note the ring gear backlash. Refer to the Check Hypoid Gear Set Backlash in Section 8.
  • Page 13 Section 2 Disassembly Disassemble the Differential and Ring Figure 2.22 Gear Assembly 1. Remove the capscrews that hold the case halves together. Figure 2.20 . 2. Separate the flange case half from the ring gear using an appropriate puller. Figure 2.21 . 3.
  • Page 14 Section 2 Disassembly 7. Using a vise, secure the case. Remove the Figure 2.29 fasteners. Figure 2.26. 8. Separate the case halves. Remove the internal components in the sequence specified in Figures 2.27, 2.28, 2.29 and 2.30. To disassemble the case, use a press or a hammer and a brass bar, making contact with the inner surface of the case.
  • Page 15 Section 2 Disassembly 9. Lower the case from the tool. Figure 2.33 10. Mark the side gear shafts and the case before disassembly so that the original position of the PLANETARY OUTER parts is kept when reassembling. GEAR WASHER 11. Using a hammer and a punch, lightly tap the pin towards the inside of the gear enough ROLL to free the shaft for removal.
  • Page 16 Section 2 Disassembly 2. Remove the yoke using an appropriate yoke 4. Remove the pinion case fastening screws and puller. Figure 2.35. washers. Figure 2.37. Figure 2.37 Figure 2.35 CAUTION CAUTION Do not insert wedges or chisels between the Do not use a hammer to remove the pinion oil pinion and differential cases.
  • Page 17 Section 2 Disassembly Disassemble the Drive Pinion and Figure 2.40 Bearing Cage DRIVE PINION Figure 2.39 PRESS OIL SEAL OIL SEAL DRIVE PINION BEARING CAGE OUTER BEARING (CUP AND CONE) SUPPORT SUPPORT SPACER SPIGOT BEARING INNER BEARING (CUP AND CONE) 5.
  • Page 18 Section 2 Disassembly Figure 2.43 WARNING Observe all warnings and cautions provided by PRESS the press manufacturer to avoid damage to DRIVE components and serious personal injury. PINION INNER 7. If you need to replace the pinion bearings, BEARING CONE remove the inner and outer bearing cups from BEARING the inside of cage.
  • Page 19 Section 2 Disassembly 10. Remove the snap ring (if applicable) from the end of drive pinion with snap ring pliers that expand. Figure 2.45. 11. Remove the spigot bearing from the drive pinion with a bearing puller. Figure 2.46. 12. If equipped with a two-piece spigot bearing, remove the inner race from the pinion using a bearing puller.

  • Page 20: Section 3: Prepare Parts For Assembly

    Section 3 Prepare Parts for Assembly 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 21: Dry Parts After Cleaning

    Section 3 Prepare Parts for Assembly Dry Parts After Cleaning 2. The radius at the large diameter end of the rollers is worn to a sharp edge. Figure 3.1. 1. Parts must be dried immediately after cleaning A visible roller groove in the cup or the cone and washing.
  • Page 22 Section 3 Prepare Parts for Assembly Hypoid Generoid Ring Gear and Pinion Figure 3.3 Inspect the ring gear and pinion assembly for wear or damage, such as cracks, depressions, scores and chips. Check the seats of the bearing cones and the splines of the pinion. NOTE: The generoid hypoid drive pinions and ring gears are machined in matched sets to ensure the ideal position of tooth contact.

  • Page 23: Storage

    Section 3 Prepare Parts for Assembly 4. Check the mounting surface for the side gear shafts in the case halves. Check that the bores are free of burrs at both ends. 5. Inspect the diameters of the side gear shafts. If any should show signs of wear, grooves, depressions, etc., replace them all.

  • Page 24: Section 4: Adhesives

    Use a wire brush. Do not place adhesive on threaded areas. Figure 4.2 . 2. Apply four or five drops of Meritor Liquid Adhesive, Loctite 680 or equivalent inside each threaded hole or bore ONLY. Make sure the adhesive is applied inside to the bore threads.
  • Page 25 15 minutes. Have your eyes checked by a doctor as soon as possible. The following silicone gasket products or equivalent can be used for Meritor components: Three Bond Liquid Gasket No. TB 1216 (Grey) Loctite Ultra Grey Adhesive/Sealant #18581 Meritor part number 2297-F-7052 0.125"...

  • Page 26: Features Of Liquid Adhesives

    6. Wait 20 minutes before filling the assembly each fastener. Apply the minimum torque value with lubricant. recommended by Meritor. If the fastener does not turn, remove it and follow the procedure Features of Liquid Adhesives described in this section.

  • Page 27: Chemical Gasket Material

    Chemical gasket material is a substance with a pasty consistency that sets at ambient temperature forming a resistant packing. The gasket materials adopted by Meritor are FAG 3 (Loctite) and Neutral Silicone (Dow Corning 768 or Rhodia 567/666). Clean Parts...

  • Page 28: Section 5: Assembly

    Section 5 Assembly Section 5 Assembly Figure 5.1 WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Assembly Assemble the Drive Pinion, Bearings and Bearing Cage 1. Check that the cup seatings are clean and free of burrs.
  • Page 29 Section 5 Assembly 7. Rest an appropriate driver on the press table 10. Press the pinion until it rests firmly against the and position the new spigot bearing on the spigot bearing. driver. Figure 5.5 . 11. Release the pressure and lower the drive 8.
  • Page 30 Section 5 Assembly 17. Install a new pinion seal using an appropriate Figure 5.12 tool. Figure 5.10 . 18. Apply lithium soap grease to the lips of the ADJUSTMENT SPACERS seal and apply pressure. Figure 5.11 . FOR THE DRIVE PINION BEARINGS 19.
  • Page 31 Section 5 Assembly Determine Bearing Preload Table B: Model 240 Thickness Thickness Using a Press Code Code 1. Lubricate all the drive pinion bearings with 029034 18.30 029053 18.79 the oil specified in Section 6. 029035 18.33 029054 18.82 029036 18.35 029055 18.85...
  • Page 32 Section 5 Assembly 5. Write down and record the torque value after Examples of Calculations Data the cage starts, not the starting torque. Radius – 8.4 cm (3.31-inches) Figure 5.13. Dynamometer reading 2.3 kg (5.0 lb) Calculation Procedure Figure 5.13 2.3 kg x 8.4 cm = 19.3 kg per square cm PRESS 5.0 lb x 3.31-inches = 16.55 lbs per square inch...
  • Page 33 Section 5 Assembly Select Drive Pinion Bearing Cage Figure 5.15 Adjustment Shims This adjustment helps to position the drive pinion in relation to the ring gear for the purpose of ensuring the ideal position of tooth contact. The desired distance is obtained by the installation of a shim packet below the drive pinion bearing case.
  • Page 34 Section 5 Assembly Example of Calculation “1” Without Using Caliper This process consists of a mathematical Data: calculation, and the result is sufficiently accurate PT (original pack)......0.09 when the ring gear and drive pinion set is replaced.
  • Page 35 Section 5 Assembly The special tool contains the following Figure 5.19 components. Figure 5.17. Figure 5.17 CENTERING CENTERING DISCS AXLE SHAFT DIAL ADAPTERS FOR INDICATOR THE DRIVE PINION REAR BEARING Figure 5.20 DRIVE PINION SIMULATOR SHIM PACKS SPLINED NUT FRONT DRIVE PINION BEARING RETENTION WASHER 2.
  • Page 36 Section 5 Assembly 6. Install the drive pinion front bearing lock Figure 5.23 washer and the splined nut, tightening manually. Figure 5.22. 7. Check if the drive pinion and the carrier surface contacts are clean and free of scratches or scores. 8.
  • Page 37 Section 5 Assembly 14. Install the shim pack on the top of the drive Figure 5.28 pinion simulator after checking if the contact surfaces of both parts are absolutely clean. Figure 5.26. 15. Install a dial indicator in the holder. Place the holder and the indicator pointer on the gauge surface of the shim and adjust the dial to zero (0).
  • Page 38 Section 5 Assembly 18. Check and write down the number engraved From these values we can determine the corrected on the end of the pinion. This value indicates specific nominal dimension (Csnd): how many hundredths of a millimeter have to Number –6 engraved on the end of the drive be added or subtracted from the corrected pinion signifies that the variation in the height of...
  • Page 39 Section 5 Assembly Assemble the Main Differential and 2. Install the drive pinion bearing cage. Figure 5.32. Ring Gear Assembly 3. Install the washers and fasteners and tighten 1. Apply Shell 71032 Alvania EP-2 or them to the torque value specified in Texaco 995 Multifak EP-2 grease in the Section 7.
  • Page 40 Section 5 Assembly 5. Install the roller pins. Figure 5.37. Figure 5.39 6. Hold the main differential case (side gear half) using an appropriate device. Figure 5.38. 7. Position the tapered side gear (short hub) with its thrust gear in the case. Figure 5.39. 8.
  • Page 41 Section 5 Assembly Figure 5.43 WARNING Take care when you use Loctite to avoid serious personal injury. Follow the manufacturer’s instructions to prevent irritation to the eyes and skin. 15. Apply Loctite No. 271 or Three Bond 1305 liquid adhesive to the threads of the remaining fasteners for the main differential case assembly.
  • Page 42 Section 5 Assembly 3. Install the left side adjusting ring (ring gear WARNING side) first to prevent movement that would hinder the assembly operation. Take care when you use Loctite to avoid serious personal injury. Follow the manufacturer’s 4. Install the adjustment nuts, turning them instructions to prevent irritation to the eyes normally until they contact the bearings.
  • Page 43 Section 5 Assembly Models 230/240 WARNING A. Install the four lock plate fastening studs Take care when you use Loctite to avoid serious so that there is a 1.05-1.07-inch personal injury. Follow the manufacturer’s (26.6-27.2 mm) space between the top instructions to prevent irritation to the eyes of the studs and the machined surface of and skin.
  • Page 44 Section 5 Assembly 4. Apply 3M Industrial Adhesive 847 to the outer 5. Slowly press on the center of the diaphragm surface of the plugs. without forcing it, until it touches the base of the mechanism. 5. Install the new plugs and the shift shaft. Figure 5.51.
  • Page 45 Section 5 Assembly Adjust the Ring Gear Thrust Screw CAUTION Model 240 Do not try to install the differential using a hammer because this could deform the flange 1. After you have made the adjustments to the and cause oil leaks. assembly, install the thrust screw and nut until the tip contacts the rear surface of the ring 7.

  • Page 46: Section 6: Lubrication

    Magnetic Plug oil fill and level check hole. The axle must not be washed internally with any Meritor recommends the use of magnetic plugs type of solvent (kerosene, gasoline, diesel oil, for the axle oil draining port. etc.). After each oil change and before returning the vehicle to normal operation, drive it, limiting NOTE: The magnetic plug loses its efficiency very...

  • Page 47: Section 7: Specifications

    Section 7 Specifications Section 7 Specifications The torque values indicated apply to parts covered with a thin film of anticorrosive oil. For dry parts, apply a torque value 10% higher than that specified. For parts lubricated with oil from the unit, apply a torque value 10% lower than that specified.

  • Page 48: Section 8: Adjustments And Preloads

    Section 8 Adjustments and Preloads Section 8 Adjustments and Preloads Figure 8.3 WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Adjustments and Preloads Determine Preload 1. Secure the main differential case assembly. Engage the tool with the splines of one of the differential side gears.

  • Page 49: Alternative Method

    Section 8 Adjustments and Preloads Alternative Method 7. The differential case (flange and plain half) and the lock plate must be inspected and replaced if they present assembly difficulties. CAUTION 8. Check the runout of the rear surface of the ring Always use a “T”...
  • Page 50 The value for the backlash should be between 0.010- to 0.016-inches (0.25-0.40 mm). Figure 8.12 If you reuse the hypoid gear set: Meritor recommends that the original backlash (measured before disassembling the differential) be maintained.
  • Page 51 Section 8 Adjustments and Preloads Correct Contact Patterns Figure 8.15 For clarification purposes, Figure 8.13 offers the terminology used in this section. The contact pattern for the manual process indicates that the position of the gears is correct, covering a contact area from the center to the toe and the heel/top and the root of the tooth.
  • Page 52 Section 8 Adjustments and Preloads Tooth Pattern Variations Figure 8.18 Immediately check if the contact shows variation with respect to the tooth pattern. If variation should exist, alter the depth of the ring gear by varying the backlash. Refer to Table J. Table J Contact Obtained Meaning...
  • Page 53 Meritor Heavy Vehicle Systems, LLC 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. ArvinMeritor Commercial Vehicle Systems reserves the right to revise Troy, MI 48084 USA the information presented or discontinue the production of parts described at any time.

This manual is also suitable for:

Rs-230Rs-240

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