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Meritor 18X Maintenance Manual

Single reduction differential carrier
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Maintenance Manual MM-10127
Single Reduction Differential Carrier
18X
Issue September 2017

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  • Page 1 Maintenance Manual MM-10127 Single Reduction Differential Carrier Issue September 2017...

  • Page 2: Service Notes

    MERITOR. MERITOR reserves the right to publish revisions at any time for technical or Meritor uses the following notations to alert the user of possible commercial purposes.
  • Page 3 81 Section 9: Appendix 51 Section 5: Differential Lock Removal Available spacers and combination of calculated Differential Lock Removal spacers 53 Section 6: Tightening Torque Values & Lubrication Section view Tightening Torque Table 57 Section 7: Troubleshooting Troubleshooting Chart Meritor Differential Carrier 18X...

  • Page 4: Terms Used In This Manual

    Operator: Further information on warranty conditions may be obtained Any person who will use the Single Reduction Differential Carrier directly from the manufacturer or by referring to the Meritor web as part of a more complex device. site www.meritor.com Meritor Differential Carrier 18X...
  • Page 5 Introduction Specification & Data Exploded View Exploded View Parts List Section View Section View Parts List Meritor Differential Carrier 18X...

  • Page 6: General Description

    The differential assembly drive gear welded is supported on two taper roller bearings and is adjusted for end play through two threaded ring nut adjusters. Meritor Differential Carrier 18X...

  • Page 7: Specifications And Data

    Pinion Bearing Preload 4 - 8 Nm without Pinion Seal * Verify with the Engineering reference the range of the ratio in current production because sometimes some ratios could be already released but not currently in production. Meritor Differential Carrier 18X...
  • Page 8 1 Introduction Exploded view Fig. 1.1 Meritor Differential Carrier 18X...

  • Page 9: Exploded View Parts List

    10a Inner Pinion Bearing Cup 10b Inner Pinion Bearing Cone Spacer (Variable) Shim - Inner Pinion Bearing Cup (0.10mm) Shim - Inner Pinion Bearing Cup (0.15mm) Shim - Inner Pinion Bearing Cup (0.35mm) Shim - Inner Pinion Bearing Cup (0.50mm) Meritor Differential Carrier 18X...
  • Page 10 1 Introduction Section view Left Right Bearing Cap Bearing Cap Fig. 1B Meritor Differential Carrier 18X...
  • Page 11 Pinion Seal Outer Pinion Bearing Spacer (variable) Diff Carrier Shim (variable) Inner Pinion Bearing Drive Pinion Spigot Bearing Bearing Cap LH Bearing Cap Screw Bearing Cap RH Differential Gear Set Assembly Sensor Switch Locknut - Sensor Switch Meritor Differential Carrier 18X...
  • Page 12 Meritor Differential Carrier 18X...

  • Page 13: Maintenance

    Ring Gear & Pinion Adjustment Shim Pack Calculation Carrier Assembly Calculating the Preload Spacer Differential Preload Adjust Differential Bearings Preload Tooth Contact Patterns & Hypoid Gear Set Installation & Adjustment of the Diff Lock Sensor Switch Meritor Differential Carrier 18X...

  • Page 14: Spare Parts

    Use original Meritor spare parts only. sealing. DO NOT apply the sealant over the slots (Fig 2.1a). Differential removal and installation NOTE: For detailed information see Meritor Manual no. MM1114 Slot or the vehicle manufacturer manuals. Sealant Continuous bead 1.
  • Page 15 If the tool is not available press the bearing with 1.000 N or 100 kg load and take measurement in three points - about 120 degrees. Only original Meritor spare parts should be used. Use of non-original parts could seriously affect differential Measure the internal distance between the service tool plates at unit performance.
  • Page 16 1.1 The standard theoretical pinion mounting dimension F is 255mm 1.2 Note the Pinion Cone (P.C.) value H marked on the drive ring gear (Fig. 2.6). This can be either a + value or - value, (e.g. + 0.10mm) Fig. 2.6.c Meritor Differential Carrier 18X...
  • Page 17 2 Maintenance Refer to the following examples which cover all the possible calculation combinations. NOTE : All values are mm. Example 1: Original Shim Pack Thickness 0.76 marked on the OLD DRIVE GEAR (-0.10) -0.10 Resulting Value 0.66 marked on the NEW DRIVE GEAR (-0.12) +0.12 Thickness of new shim pack required 0.78...

  • Page 18: Carrier Assembly

    Manufacturer’s Adjusted Shim Pack value which is 0,6 mm for the 18X carrier. Check tooth contact pattern and adjust the shim pack thickness as necessary to achieve the correct contact pattern.
  • Page 19 When under cutting of the pinion nose is present it may be necessary to adjust the position of the staking points to ensure they avoid any undercut; in this case a minimum of Fig. 2.14 5 staking points are required. Meritor Differential Carrier 18X...
  • Page 20 Press the bearing until is squarely against the shoulder in the (MST4902) bottom of its bore (Fig.2.18). Assembly Oil MST4802 Fig. 2.15 Fig. 2.17 MST4902 Fig. 2.16 Fig. 2.18 CAUTION: Cups must be firmly seated in the bore- Check with feeler gauge (0.02mm) after installation. Meritor Differential Carrier 18X...
  • Page 21 (Fig 2.20). shoulder in the bottom of its bore (Fig.2.22). Apply a press load of 6 - 8 ton. Fig. 2.19 Fig. 2.21 Outer Shims Shims Inner Fig. 2.20 Fig. 2.22 Meritor Differential Carrier 18X...
  • Page 22 Pinion Head Support Fig. 2.24 NOTE : Do not use a standard flange and pinion nut for this operation. Use a set up pinion nut. * See appendix 9 of the available double spacers combination. Meritor Differential Carrier 18X...
  • Page 23 (Fig. 2.26) Fig. 2.26 11. Refit flange and pinion lock nut only to set pre-load on bearings. (Fig. 2.27) Fig. 2.27 12. Lock flange with service tool MST4400 - CT13 (Fig. 2.28) Fig. 2.28 Meritor Differential Carrier 18X...
  • Page 24 17. Remove the outer bearing cone and master spacer. 18. Position the calculated spacer identified above to provide the correct bearing pinion preload (Fig.2.31) and continue assembling the carrier. Wooden Block Pinion Head Support Fig. 2.31 Meritor Differential Carrier 18X...
  • Page 25 The flange must be held with a suitable tool (MST4400-CT13) to tighten the nut and a torque multiplier will be required to achieve the correct torque value of 2000 - 2500 Nm. (Fig.2.33) Fig. 2.33 Meritor Differential Carrier 18X...
  • Page 26 Preload decrease the bearing spacer combination. Without • To decrease preload: Pinion Seal increase the bearing spacer combination. 22. If the torque preload is correct see Section 4 for Assembly flange and pinion seal. Fig. 2.34 Meritor Differential Carrier 18X...
  • Page 27 6 - 8 tons. NOTE : The larger bearing is fitted to the drive gear side of the ring gear. Fig. 2.35 Fig. 2.36 Fig. 2.37 Fig. 2.38 Meritor Differential Carrier 18X...
  • Page 28 (Fig.2.40). Fit the cap into position on the Differential (Fig.2.41). Fig. 2.41 Fig. 2.39 Fig. 2.42 3. Safely lift the differential with ring gear, cup, R.H. cap and adjusting ring assembly (Fig.2.42) using a suitable tool (MST4712 - CT52). Fig. 2.40 Meritor Differential Carrier 18X...
  • Page 29 (Fig.2.45). Tighten all the cap screws by hand four to six turns, then tighten to the correct torque value 200Nm+ 90°-105°. Fig. 2.43 Fig. 2.45 5. Fit the L.H. split cap with a light plastic or rubber mallet (Fig.2.44). Fig. 2.44 Fig. 2.46 Meritor Differential Carrier 18X...
  • Page 30 Fig. 2.49 Adjust Differential Bearings Preload 1. Fit two dial indicators according to the above scheme on “X” or “Y” axis against the wing’s caps and set in the ZERO position. Fig.2.50 Fig. 2.48 Fig. 2.50 Meritor Differential Carrier 18X...
  • Page 31 3, max 4 notches from cap’s mark. Fig. 2.53 “Zero” Preload Fig. 2.52 Fig. 2.51 3-4 Notches Fig. 2.53 Fig. 2.54 * Adjusting rings could differ from original shape for clarity. NOTE: Differential Bearing Cap (X or Y) Divergence = 0.15 - 0.33 mm Meritor Differential Carrier 18X...
  • Page 32 7. Check the gear for run out (Fig.2.58). If run out exceeds 0.20 NOTE : Adjust the backlash by moving the gear only. mm, remove the differential and check for the cause. Fig. 2.55 Fig. 2.57 Fig. 2.56 Fig. 2.58 Meritor Differential Carrier 18X...
  • Page 33 (Fig.2.59). Coast (concave side) Tighten the screws to the correct torque value 10-12 Nm. Drive (convex side) Heel 1 - Coast 2 - Toe 4 - Heel 3 - Drive Fig. 2.59 Fig. 2.56 Meritor Differential Carrier 18X...

  • Page 34: Differential Lock

    1. Coat the shift fork slanting face with Molikote Gn Plus grease (Fig.2.60). 2. Install the shift fork into position in the carrier case with the protruding boss facing towards the outer bore in the differential lock housing (Fig.2.61). Fig. 2.61 Meritor Differential Carrier 18X...
  • Page 35 3. Compress the shift shaft spring (650 N. or 65 Kg force) using 4. While the spring is compressed insert it into a service tool a Meritor suitable service tool MST4708 - CT48 MST4211 - CT07 and remove from the spring compression (Figs.2.62 &...
  • Page 36 Fig. 2.66 Fig. 2.69 Fig. 2.67 6. With a Meritor suitable service tool MST4709 - CT49, or a suitable screwdriver locate the spring correctly between the two shift shaft bores into the carrier casting (Fig.2.68). 7. Whilst holding and tilting the shift fork, place the shift collar in position in the fork (Fig.
  • Page 37 The old Piston&Push-rod and the new Push-rod are Generously lubricate the 'O' ring, piston (Fig.2.73) with interchangeable. Molikote 44 grease and carefully insert the piston into the cylinder bore (Fig.2.74). Fig. 2.71 Fig. 2.73 Fig. 2.72 Fig. 2.74 * Single version Fig. 2.75 Meritor Differential Carrier 18X...
  • Page 38 1. Before fitting the switch, coat the switch point with MoliKote GN Plus grease. Apply Loctite 573 sealant to the threads (Fig. 2.78) and carefully screw the switch into the differential casing approx. 3 threads (Fig. 2.79). Fig. 2.76 Fig. 2.78 Fig. 2.77 Fig. 2.79 Meritor Differential Carrier 18X...
  • Page 39 6. Repeat the above operations several times before running on the road. Fig. 2.80 NOTE : for the correct use of the Meritor Driver Controlled Main Differential Lock (DCDL) see TP9646 Meritor site. Fig. 2.81 Meritor Differential Carrier 18X...
  • Page 40 Meritor Differential Carrier 18X...
  • Page 41 Hypoid Gear Contact Patterns Hypoid Gear Pattern Tables Meritor Differential Carrier 18X...
  • Page 42 : Check the Backlash, ADD Shims and re-set the Backlash CONDITION “C” HEEL HEEL BOTTOM BOTTOM • DRIVE-COAST SIDE : Contact too close to the BOTTOM • CORRECTIVE ACTIONS : Check the Backlash, REDUCE Shims and re-set the Backlash. Meritor Differential Carrier 18X...
  • Page 43 : Contact too close to the TOE. • COAST SIDE : Contact too close to the HEEL. • CORRECTIVE ACTIONS : Increase the backlash. : The Contact patterens reported are always on the RING GEAR TEETH. NOTE Meritor Differential Carrier 18X...
  • Page 44 Meritor Differential Carrier 18X...

  • Page 45: Pinion Seal Replacement

    Pinion Seal Replacement Disassembly Assembly Meritor Differential Carrier 18X...
  • Page 46 6. If you do not discard the pinion nut and flange, mark the flange position on the pinion and remove it. This may require the use of a standard bearing puller tool. (Fig. 4.4) Fig. 4.4 Meritor Differential Carrier 18X...
  • Page 47 Discard seal and replace with new for rebuild (Fig. 4.6) MST4808. MST4401 - CT14 Seal Outer Case Fig. 4.8 4. Insert seal outer case into service tool MST4410 - CT26 (Fig.4.9) Fig. 4.6 Seal Outer Case Fig. 4.9 Meritor Differential Carrier 18X...
  • Page 48 8. Refit flange and pinion nut. (Fig. 4.13) Fig. 4.11 Fig. 4.13 NOTE : The marks on Pinion and reused flange must now be rotated at 90° avoiding same staking location on nut. Skip note if you use new flange seal nut. Meritor Differential Carrier 18X...
  • Page 49 11. With a suitable ball nosed punch, indent lock nut in two places directly above the slots in the flange. (Figs. 4.16 and 4.17) Fig. 4.14 10. Tighten flange lock nut to a torque of 2000-2500Nm (Fig. 4.15) Fig. 4.16 Fig. 4.15 Fig. 4.17 Meritor Differential Carrier 18X...
  • Page 50 Meritor Differential Carrier 18X...
  • Page 51 Differential Lock Removal Differential Lock Removal Meritor Differential Carrier 18X...
  • Page 52 If there is a doubt in the suitability of any component for further service, replace with new Meritor service parts. 1. Remove the carrier assembly from the vehicle as described in Section 2, Maintenance and mount securely in a suitable 12.
  • Page 53 Tightening Torque Values & Lubrication Torque values Tightening Torque Table Meritor Differential Carrier 18X...
  • Page 54 6 Tightening Torque Values & Lubrication Left Right Bearing Cap Bearing Cap Fig. 6.1 Meritor Differential Carrier 18X...

  • Page 55: Tightening Torque Table

    Lubrication Oil Specification Oil Capacity Hypoid Gear Oil MS 18X = 14.5 ÷ 15 Litres • S.A.E. J2360 - GL5 - tested and approved NOTE For additional information about lubricant please refer to TP0838 and TP0445. Meritor Differential Carrier 18X...
  • Page 56 12 Axle shaft screw M16X2 [**] 235 ÷ 289 Preferred method: Torque + angle Axle shaft screw: for additional details please refer to Meritor manual no. MM1114 NOTE Tighten the fasteners in pairs opposite each other. NOTE For propeller shaft connection, please refer to OEM manual.

  • Page 57: Troubleshooting

    Troubleshooting Troubleshooting Chart Meritor Differential Carrier 18X...
  • Page 58 Clean threads, coat with sealant if necessary, and tighten to the specified torque Seal between axle housing and differential unit Remove differential unit, check and clean all is damaged sealing surfaces and coat parts concerned with sealant, as required Meritor Differential Carrier 18X...

  • Page 59: Service Tools

    Outer Bearing Cup Tool (Pinion) 75 MST4901 Inner Bearing Cone Tool (Pinion) 76 MST4804 Outer Bearing Cone Tool (Pinion) 77 MST4903 Diff. Bearing Cone L/H Tool 78 MST4905 Axle Shaft Punch Tool 79 MST4807 Inner deflector 80 MST4808 Inner ring Meritor Differential Carrier 18X...
  • Page 60 8 Service Tools MST4209 - CT05 Keying Tool - Spigot Bearing Fig. 8.1 Meritor Differential Carrier 18X...
  • Page 61 8 Service Tools MST4210 - CT06 Keying Tool Punch - Spigot Bearing Pinion Fig. 8.2 Meritor Differential Carrier 18X...
  • Page 62 8 Service Tools MST4216 - CT12 Wrench - Adjusting Ring Fig. 8.3 Meritor Differential Carrier 18X...
  • Page 63 8 Service Tools MST4400 - CT13 Flange lock tool Fig. 8.4 Meritor Differential Carrier 18X...
  • Page 64 8 Service Tools MST4401 - CT14 Seal removal tool Fig. 8.5 Meritor Differential Carrier 18X...
  • Page 65 8 Service Tools MST4410 - CT26 Fitting tool - Pinion Shaft Seal Fig. 8.6 Meritor Differential Carrier 18X...
  • Page 66 8 Service Tools MST4707 - CT47 Diff. Bearing Cone R/H Tool Fig. 8.7 Meritor Differential Carrier 18X...
  • Page 67 8 Service Tools MST4708 - CT48 Diff Lock Spring Compression Tool Fig. 8.8 Meritor Differential Carrier 18X...
  • Page 68 8 Service Tools MST4709 - CT49 Diff. Lock Spring Fitting Tool Fig. 8.9 Meritor Differential Carrier 18X...
  • Page 69 8 Service Tools MST4712 - CT52 Diff & Crown Wheel lifting Tool Fig. 8.10 Meritor Differential Carrier 18X...
  • Page 70 8 Service Tools MST4713 Wrench - Adjusting Ring LH Fig. 8.11 Meritor Differential Carrier 18X...
  • Page 71 8 Service Tools MST4714 Wrench - Adjusting Ring RH Fig. 8.12 Meritor Differential Carrier 18X...
  • Page 72 8 Service Tools MST4904 Inner Pinion Bearing Measuring Tool Fig. 8.13 Meritor Differential Carrier 18X...
  • Page 73 8 Service Tools MST4902 Inner Bearing Cup Tool (Pinion) Fig. 8.14 Meritor Differential Carrier 18X...
  • Page 74 8 Service Tools MST4802 Outer Bearing Cup Tool (Pinion) Fig. 8.15 Meritor Differential Carrier 18X...
  • Page 75 8 Service Tools MST4901 Inner Bearing Cone Tool (Pinion). Fig. 8.16 Meritor Differential Carrier 18X...
  • Page 76 8 Service Tools MST4804 Outer Bearing Cone Tool (Pinion) Fig. 8.17 Meritor Differential Carrier 18X...
  • Page 77 8 Service Tools MST4903 Diff. Bearing Cone L/H Tool Fig. 8.18 Meritor Differential Carrier 18X...
  • Page 78 8 Service Tools MST4905 Axle Shaft Punch Tool Fig. 8.19 Meritor Differential Carrier 18X...
  • Page 79 8 Service Tools MST4807 Inner deflector Fig. 8.20 Meritor Differential Carrier 18X...
  • Page 80 8 Service Tools MST4808 Inner ring Fig. 8.21 Meritor Differential Carrier 18X...
  • Page 81 Appendix Available spacers and combination of calculated spacers Meritor Differential Carrier 18X...
  • Page 82 9 Appendix Available spacers Available spacers Spacer 9,230 9,250 9,270 9,290 9,310 9,330 9,350 9,370 9,390 9,410 9,430 9,450 9,470 9,490 9,510 9,810 10,110 13,130 13,410 13,710 14,010 Meritor Differential Carrier 18X...
  • Page 83 21 + 11 23,440 20 + 12 23,160 21 + 12 23,460 20 + 13 23,180 21 + 13 23,480 20 + 14 23,200 21 + 14 23,500 20 + 15 23,220 21 + 15 23,520 Master Spacer Meritor Differential Carrier 18X...
  • Page 84 Meritor HVS Cameri S.p.A. Strada Prov. Cameri-Bellinzago km. 5 Printed in Italy 28062 Cameri (NO), Italy Tel.: +39 0321 4231 Revision September 2017 Fax: +39 0321 423424 www.meritor.com © Meritor 2012 M.graph - MM10127...

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