mm-0700 draft 9 feb 07.qxp

Maintenance manual no. MM-0700EN

Single Reduction DifferentialCarrier 17X

Issue 02/2002

Issue: February 2007

ArvinMeritor

Note

Click on the top of any page to return to the Contents page.

ArvinMeritor Differential Carrier 17X 2

pg. 06 Section 1: Introductionpg. 7 Specification & Datapg. 8 Exploded Viewpg. 9 Exploded View Parts Listpg. 10 Section Viewpg. 11 Section View Parts List

pg. 12 Section 2: Maintenencepg 13 Differential Removal & Installationpg 13 Checking Rear Axle Housingpg 14 Ring Gear & Pinion Adjustmentpg 17 Carrier Assemblypg 21 Calculating the Preload Spacerpg 30 Tooth Contact Patterns & Hypoid Gear Setpg 36 Installation & Adjustment of the Diff Lock Sensor Switch

pg. 39 Section 3: Hypoid Gear Patternspg 40 Hypoid Gear Pattern Tables

pg. 43 Section 4: Pinion Seal Replacementpg 44 Disassemblypg 45 Assembly

pg. 47 Section 5: Differential Lock Removalpg 48 Differential Lock Removal

pg. 49 Section 6: Tightening Torque Values & Lubricationpg 50 Tightening Torque Tablepg 50 Oil Specificationpg 50 Oil Change Intervalspg 50 Oil Capacity

pg. 51 Section 7: Troubleshootingpg 52 Troubleshooting Chart

Contents

ArvinMeritor Differential Carrier 17X3

All rights reserved.No part of this publication may be reproduced in any form orby any means or granted to any third parties without thewritten permission of ARVINMERITOR.ARVINMERITOR reserves the right to publish revisions at any time for technical or commercial purposes. Therefore all material contained in this manual isbased on the latest information available at time of publicationapproval.

Copyright 2007 by ARVINMERITOR Document No. MM-0700ENEdition: February 2007

Before You BeginThis publication provides installation and maintenance proceduresfor the Single Reduction Differential Carrier X17 produced byARVINMERITOR HVS

The information contained in this publication was current at thetime of printing and is subject to revision without notice or liability.

You must understand all procedures and instructions before youbegin maintenance and service procedures.

You must follow your company's maintenance andservice guidelines.

You must use special tools, when required, to avoid seriouspersonal injury and damage to components.

Meritor uses the following notations to alert the user of possiblesafety issues and to provide information that will help to preventdamage to equipment and components.

WARNINGA WARNING indicates a procedure that you must

follow exactly to avoid serious personal injury.

CAUTIONA CAUTION indicates a procedure that you must

follow exactly to avoid damaging equipment or components.Serious personal injury can also occur.

NOTE: A note indicates an operational, procedure or instructionthat is important for proper service. A NOTE can also supplyinformation that will help to make service quicker and easier.

This symbol indicates that you must tighten fasteners toa specific torque.


Access Information on ArvinMeritor's WebSiteAdditional maintenance and service information for ArvinMeritor'scommercial vehicle systems component lineup is also available atwww.arvinmeritor.com.

To access information, click on Products & Services/Literature onDemand..

Information contained in this publication was in effect at the time the

publication was approved for printing and is subject to change without

notice or liability. ArvinMeritor Commercial Vehicle Systems reserves the

right to revise the information presented to discontinue the production of

parts described at any time.

Service Notes

www.arvinmeritor.com

Service Notes

Terms used in this manualManufacturer:

ARVINMERITOR

Manual:

Maintenance manual no. MM- 0700 EN

Device:

Single Reduction Differential Carrier 17X

Technician:

Qualified personnel working on differential maintenance andservicing.

Maintenance and servicing:

Maintenance and servicing refer to periodical checks and/orreplacement of differential parts or components. It also refers tothe determining of the cause of a malfunction in order to restorethe initial operating conditions.

Operator:

Any person who will use the differential as part of a more complexdevice.


Warranty

Warranty applies to the differential unit installed on vehicles forwhich it was designed. Warranty is void in the following cases:

• Improper use of the vehicle on which the differential is installed (usage conditions, overloading etc.)

• Tampering with vehicle components that may affect rear axleperformance.

• Use of non-original spare parts.

• Improper installation, adjustment, repair or modification.

• Poor or improper maintenance (including consumables otherthan those specified).

Further information on warranty conditions may be obtaineddirectly from the manufacturer or by referring to the ArvinMeritorweb site at www.arvinmeritor.com

www.arvinmeritor.com


Introduction

pg. 7 Specification & Datapg. 8 Exploded Viewpg. 9 Exploded View Parts Listpg. 10 Section Viewpg. 11 Section View Parts List1


General descriptionThe differential unit is of the single-reduction type featuring a hypoidgear set. The bevel pinion is mounted on two taper roller bearingsand a third straight roller bearing. The bevel pinion setting relativeto the drive gear can be adjusted by varying the thickness of theshim pack located between the inner pinion bearing cup and thecarrier bearing shoulder. The differential gear case is supported ontwo taper roller bearings and is adjusted for end play through twothreaded ring nut adjusters.

Specifications and dataHypoid pinion bearings

2, taper roller and 1 straight roller bearing

Differential unit

2 Introduction

Final Drive Hypoid Gear Ratio 2.64 : 2.85 :3.08 : 3.36 : 3.70 :4.11 : 4.63 : 5.29 : 6.17

Pinion to Drive Gear Backlash 0.28 - 0.50 mm

Pinion to Crown Backlash Adjustment by Adjusting Rings

Differential Bearing Cap Divergence 0.15 - 0.33 mm

Differential Bearing CapDivergence Adjustment by Ring Nut Adjusters

Thickness Range for Shims fitted between Bevel Pinion Bearing Cage & Differential Carrier 0.10 - 0.15 - 0.2 - 0.5 mm

Drive Gear runout 0.20 max mm

Exploded View


2 Introduction

Fig 1.1

Inpu

t Fla

nge

& De

flect

or O

ptio

n

Diff

Lock

Cov

er O

ptio

nNo

Diff

Loc

k Op

tion

26

1615

a-1

15b-

1 14

9a32

1a

12

10b

2a

13

1g

1b

78

2b

5

4

36

1d1f

1e1f

1c

1718 19

24

22-1

23

11

28

27

15a-

215

b-2

22-2

23

29

24-2

3130

21

25

25

1g

7

8

1

10a

10

4a4b

3b

3a

24

159b

9

2

15

20

2 Introduction

Exploded View - Parts List

ITEM DESCRIPTION

1 Diff Carrier & Cap Assembly

1a Diff Carrier

1b Bearing Cap RH (Disjoint)

1c Bearing Split Cap LH

1d Capscrew - Bearing Cap RH

1e Capscrew - Bearing Cap LH

1f Washer - Bearing Cap

1g Locator Pin

2 Differential Gear Set Assembly

2a Drive Pinion

2b Diff Assembly & Drive Gear - Welded

3 Diff Bearing LH Side

3a Diff Bearing Cup LH

3b iff Bearing Cone LH

4 Diff Bearing RH Side

4a Diff Bearing Cup RH

4b Diff Bearing Cone RH

5 Adjusting Ring RH Side

6 Adjusting Ring LH Side

7 Lock - Adjusting Ring

8 Capscrew - M6 x 20

9 Outer Pinion Bearing

9a Outer Pinion Bearing Cup

9b Outer Pinion Bearing Cone

10 Inner Pinion Bearing

10a Inner Pinion Bearing Cup

10b Inner Pinion Bearing Cone

11 Spacer (Variable)

12 Shim - Inner Pinion Bearing Cup (0.10mm)

Shim - Inner Pinion Bearing Cup (0.15mm)



13 Spigot Bearing

14 Pinion Seal


ITEM DESCRIPTION

15 Companion Flange & Deflector Assy

15a - 1 Companion Flange (option 1)

15b - 1 Deflector (option 1)

15a - 2 Input Flange (option 2)

15b - 2 Deflector (option 2)

16 Pinion Nut - M45

17 Shift Fork

18 Shift Shaft

19 Piston

20 “O” Ring (40mm diameter)

21 Shift Shaft Spring

22 - 1 Diff Lock Hole Cover (option 1)

22 - 2 Diff Lock Hole Cover (option 2)

23 Gasket

24 Hex Head Capscrew - M6 x 20

24 - 2 Countersunk Head Capscrew - M6 x 20

25 Washer

26 Clutch Shift Collar

27 Lock-Nut - Sensor Switch

28 Sensor Switch

29 Hole - End Plate Cover

30 Blanking Plug - Sensor Switch Hole

31 Washer - Plug

32 Identification Plate


2 Introduction

Section View

Fig 1.2

1

2

3

5

6

8

12

17

22

16

14

26

259

4

10

11

16

2 Introduction


Section View - Parts List

ITEM DESCRIPTION

1 Pinion Nut

2 Input Flange

3 Deflector

4 Pinion Seal

5 Outer Pinion Bearing

6 Spacer (Variable)

8 Diff Carrier

9 Shim (Variable)

10 Inner Pinion Bearing

11 Drive Pinion

12 Spigot Bearing

14 Bearing Cap LH

16 Bearing Cap Screw

17 Bearing Cap RH

22 Differential Assembly

25 Sensor Switch

26 Locknut - Sensor Switch


2 Maintenance

Maintenance

pg 13 Differential Removal & Installationpg 13 Checking Rear Axle Housingpg 14 Ring Gear & Pinion Adjustmentpg 17 Carrier Assemblypg 21 Calculating the Preload Spacerpg 30 Tooth Contact Patterns & Hypoid Gear Setpg 36 Installation & Adjustment of the Diff Lock Sensor Switch2


Checking rear axle housingCheck rear axle alignment to prevent possible distortion fromcausing abnormal stress, noise and pneumatic consumption.Installation

ReassemblyClean mounting faces and threads thoroughly. Apply a continuousbead of sealant DC 7091 to the rear axle mounting face (Fig.2.1a) Ensure the continuous bead of sealant is applied around theslots in the mounting face to achieve correct sealing, DO NOTapply the sealant over the slots (Fig 2.1a).Apply sealant (Loctite 510 or 549) to the complete surface of thejoint gasket (Fig 2.1b.)

NOTE: The carrier to housing assembly must be completedwithin 15 minutes of applying the sealant to the mating surfaces.

Reverse the removal operation sequence and torque fasteningscrews/nuts and drain plug to the specifications detailed inSection 6 Tightening Torques & Lubrication.

2 Maintenance

IntroductionIn order to ensure reliable and efficient differential unit operation,maintenance intervals, use of lubricants and correct proceduresspecified by the manufacturer should be strictly observed (refer toLubrication Maintenance Manual no. 1). For further informationcontact the manufacturer’s engineering department or refer to theArvinMeritor Web site at www.arvinmeritor.com (technical library –manuals).

Spare partsUse original Meritor spare parts only.

Differential removal and installation1. If the vehicle is loaded, unload the rear axle before removingthe differential.

2. Place the vehicle on level ground and chock the front wheels.

3. Rest the rear axle on two suitably strong axle stands.

4. Remove the drain plug from the rear axle bottom end anddrain lubricant.

5. Engage differential lock before air pressure falls below 2.8bars

6. Remove axle shaft mounting screws and washers.

7. Remove axle drive shafts.

8. Remove propeller shaft.

9. Disconnect compressed air lines and differential lock sensorswitch coupling.

10. Remove differential carrier to rear axle housing fasteningscrews (leave two screws in place to prevent the differentialfrom falling).

11. Safely support carrier assembly with suitable lifting tool to aidremoval. Remove plastic protective plugs fitted to theextraction screw holes. Fit extractor screws.Remove final 2 carrier screws to withdraw carrier assembly.

Mount the carrier assembly in a suitable fixture and remove thedifferential lock assembly as described in Section 5 DifferentialLock Removal. Fig 2.1b

Fig 2.1a

Continuous bead of sealant

DC 7091

Apply sealant(Loctite 510 or 549) to the completesurface

Slot

Sealant


Measure the internal distance between the service tool plates atthree equally spaced points to determine the total width of thebearing C (Fig 2.3) (e.g. 44.63). Record dimension C it is requiredfor Shim Pack calculation below.

2 Maintenance

CAUTION: Only original Meritor spare partsshould be used.

Use of non-original parts could seriously affect differentialunit performance. Use of non-recommended lubricants willadversely affect performance and service life.

WARNING: Waste oil disposal must be carried outin conformity with the legislation in force.

CAUTION: Differential carrier removal andhandling should be performed using the specified

lifting and carrying equipment.

CAUTION: During dismantling/reassemblyoperations always engage differential lock to ensure

alignment of the splined sections and prevent shift forkbending and spline damage.

Finally ensure that:• There are no leakages from air lines.• Lubricating oil meets manufacturer’s specifications.• Differential lock cab warning lamp functions correctly.

Ring Gear & Pinion Adjustment

If a new ring gear and drive pinion are to be installed, the correctthickness of shim pack required between the inner bearing cupand the carrier must be determined.

When the correct shims pack has been identified the bearingpreload on the drive pinion must be adjusted. The preload iscontrolled by the thickness of the spacer between the inner andouter cones of the pinion bearings.

Determining the Pinion Inner Bearing DimensionBefore assembling the carrier, measure the complete inner pinionbearing assembly compressed into the ArvinMeritor service tool CT40 , as detailed below.

Place the complete bearing into service tool CT 40 and rotate itwhile tightening the tool (Fig 2.2). Tighten the tool until the bearingis completely seated (Fig 2.3).

Fig 2.2

Fig 2.3

BEARING

Identifying the Carrier Class & Pinion Mounting DimensionNote the carrier class stamped on the carrier housing D. Thismay be stamped on the carrier outer casing (Fig 2.4) or the carriermounting face (Fig 2.4a). The table (Fig 2.5) contains the crossreference detail for carrier class code D to the mounting piniondimension E (eg. 283.5mm)

NOTE: Dimension E is essential to calculate the new shim packrequirements when the original ring gear and shim pack are notavailable.


Shim Pack Calculation

Calculate the shims required using the appropriate procedure 1or 2 below.

1. Calculating the Pinion Shim Pack Value - Original Ring Gear, Pinion & Shim Pack NOT AVAILABLE for Reference

1.1 The standard theoretical pinion mounting dimension F is235mm

1.2 Note the Pinion Cone (P.C.) value G marked on the drive ring gear (Fig. 2.6). This can be either a + value or - value, (e.g. + 0.1mm)

1.3 Using the values identified for C, E, F & G above calculate the shim pack requirements using the formula provided below.

Formula: E - (F +/- G) - C = Shim Pack Value

e.g. 283.50 - (235 + 0.1) - 47.63 = 0.77mm

NOTE: Use a shim pack as close as possible to the calculationvalue obtained. Shims are available in thicknesses of 0.10, 0.15,0.2 & 0.5mm.

Fig 2.4a

Fig 2.5

Fig 2.6

Carrier Class(D)

Pinion Mounting Dimension (mm)(E)

0 283.601 283.582 283.563 283.544 283.525 283.506 283.487 283.468 283.449 283.4210 283.40

2 Maintenance

Fig 2.4

10 +0,05 1 0/00 B/L 0,32


2. Calculating the Pinion Shim Pack Value - Original Ring Gear & Pinion and Shim Pack AVAILABLE for Reference.

2.1. Measure the thickness of the shim pack removed from the old pinion/drive gear assembly. Use a micrometer or gauge and record the reading.

2.2. Read the Pinion Cone (P.C) value marked on the drive ring gear which is to be replaced (Fig. 2.6)If it is a plus (+) number add it to the value recorded at point 2.1.If it is a minus (-) number, subtract it from the value recorded at point 2.1.

Record the result of the above calculation.

WARNING: The value obtained at point 2.2 abovewill be used to calculate the thickness of the shim

pack required to be fitted between the INNER pinion bearingcup and the differential carrier to ensure a correct new finaldrive assembly. Spare shims which may be required betweenthe INNER pinion bearing cup and differential carrier areavailable in thicknesses of 0.10, 0.15, 0.2 & 0.5mm

2.3. Read the P.C. marked on the new drive gear (Fig 2.6). Either,add or subtract from the calculated value recorded at point 2.2above.

NOTE: Where the PC figure on the NEW drive gear is a + value itmust be subtracted from the calculated value at point 2.2. Wherethe PC figure on the NEW drive gear is a - value it must be addedto the calculated value at point 2.2

Refer to the following examples which cover all the possiblecalculation combinations.

NOTE: All values are mm.

Example 1:Original Shim Pack Thickness 0.75P.C. marked on the OLD DRIVE GEAR -0.10Resulting Value 0.65

P.C. marked on the NEW DRIVE GEAR +0.20Thickness of new shim pack required 0.45

(0.65 - 0.20)

Example 2:Original Shim Pack Thickness 0.65P.C. marked on the OLD DRIVE GEAR +0.10Resulting Value 0.75

P.C. marked on the NEW DRIVE GEAR +0.20Thickness of new shim pack required 0.55

(0.75 - 0.20)Example 3:Original Shim Pack Thickness 0.70P.C. marked on the OLD DRIVE GEAR +0.10Resulting Value 0.80

P.C. marked on the NEW DRIVE GEAR -0.20Thickness of new shim pack required 1.00

(0.80 + 0.20)Example 4:Original Shim Pack Thickness 0.85P.C. marked on the OLD DRIVE GEAR -0.10Resulting Value 0.75

P.C. marked on the NEW DRIVE GEAR -0.20Thickness of new shim pack required 0.95

(0.75 + 0.20)

NOTE: Use a shim pack as close as possible to the calculationvalue obtained. Shims are available in thicknesses of 0.10, 0.15,0.2 & 0.5mm.

NOTE: All final drive sets are stamped with a number indicatingthe nominal backlash between pinion and drive gear obtainedwhen machining was completed. This backlash value is shown onthe drive gear outer diameter (Fig. 2.7)

Fig 2.7

2 Maintenance

10 +0,05 1 0/00 B/L 0,32

2 Maintenance

Carrier Assembly

If a new ring gear and drive pinion are to be installed, the correctthickness of shim pack required between the inner bearing cupand the carrier must be determined. Refer to Section 1 Ring Gear& Pinion Adjustment. When the necessary calculations have beencompleted and the correct shim pack has been identifiedcontinue with the carrier assembly detailed below.

CAUTION: Do not attempt to assemble the carrierassembly before establishing the correct shim

package requirements.

1. Where applicable, Use a suitable press and correct size sleeve,to install the dust shield (deflector) on to the companion flange(Fig. 2.8).

IMPORTANT: The spigot bearing has a larger radius on oneside. this larger radius must be positioned facing the head of thepinion (Fig. 2.9). The bearing part number should face toward theoperator.

2. Using ArvinMeritor service tool CT 5, press the spigot bearingon the nose of the drive pinion until the bearing is flat against thegear head (Fig. 2.10). Ensure the tool locates correctly on thebearing applying force to the inner ring only (Fig 2.11)


Fig 2.9

Fig 2.10

Fig 2.11Fig 2.8

A press force of 6 - 8 tons is required (Fig. 2.12).

3. Ball stake the pinion spigot in 10 places equally spaced (Fig.2.13). The ArvinMeritor service tool CT 06 has only five stakingballs present (Fig 2.14).

Mark the pinion to form a datum and the staking tool in twoplaces at a 36 degree interval (Fig 2.15).

Align one of the marks on the staking tool with the datum mark onthe pinion.Apply a load of 20 ton and form 5 staking points (4 tons perstaking point).

Remove the tool and align the second mark on the tool with thedatum mark on the pinion. Again apply a load of 20 ton to producethe second set of five staking points.

CAUTION: When under cutting of the pinion nose ispresent it may be necessary to adjust the position

of the staking points to ensure they avoid any undercut, inthis case a minimum of 5 staking points are required.


2 Maintenance

Fig 2.12

Fig 2.13

Fig 2.15Fig 2.14

36 Degrees

4. Apply assembly oil to the pinion shaft (Fig 2.16) and pressthe inner cone firmly against the pinion head shoulder usingArvinMeritor service tool CT 44, which applies pressure only onthe bearing inner cone face (Fig. 2.17). Apply a press load of 6 - 8tons.


5. Press the outer cup of pinion bearing firmly into its bore in thecarrier. Using ArvinMeritor service tool CT 43, which is the samesize as outer race (Fig. 2.18).

Press the bearing until is squarely against the shoulder in thebottom of its bore (Fig. 2.19). Apply a press load of 6 - 8 tons.

2 Maintenance

Fig 2.16

Fig 2.17

Fig 2.18

Fig 2.19

Assembly Oil

6. Fit the the correct value of shims previously calculated (Fig2.20) into base of the inner bearing bore of the carrier (Fig 2.21).


7. Apply assembly oil to the bearing seat area of the carrier (Fig2.22) and using ArvinMeritor service tool CT 42, press the bearinginto the carrier until is squarely against the shoulder in the bottomof its bore (Fig. 2.23).

Apply a press load of 6 - 8 tons.

2 Maintenance

Fig 2.20

Fig 2.21

Fig 2.22

Fig 2.23

Calculating the Pre-Load SpacerThere are two methods of determining the correct pre-load spacer,with and without ArvinMeritor service tool CT 41. Follow theappropriate procedure below.

With Service Tool CT41

8. Fit the 2 service tool spacers CT 41 (Fig. 2.24) into position inthe carrier (Fig. 2.25).


9. Using ArvinMeritor service tool CT 45, press the outer bearingcone on the pinion shaft firmly against the service tool spacers CT 41 (Fig. 2.26) using a press load of 6 - 8 ton.

CAUTION: When using a press to fit the outerbearing cone on the pinion always support the

pinion shaft with a suitable block of wood (Fig. 2.28). Failureto do this could result in damage to the carrier casting ordrive gear assembly.

2 Maintenance

Fig 2.24

Fig 2.25

Fig 2.26

Outer BearingCone

Wooden Block

PinionService ToolSpacer CT 41

If a press is not available, use ArvinMeritor service tool flange CT51 and ArvinMeritor service tool pinion nut CT 50, tighten thepinion nut to a torque value of 1350 - 1670Nm (Fig. 2.27).

NOTE: Do not use a standard flange & pinion nut for this operation.

The actions detailed above, either by press or using ArvinMeritorservice tools CT 50 & CT 51, tightend by hand, will compress theservice tool spacers CT 41.

10. Where applicable remove the service tool pinion nut CT 50and service tool flange CT 51. Remove the the outer bearing coneand service tool spacers CT 41.

NOTE: Ensure the pinion does dot drop onto the press bed whenremoving the bearing

11. Measure the new compressed thickness of the two servicetool spacers CT41, to determine the average size of each spacer.Add 0.25mm to the average value determined above and recordthis new value. Use the new value to determine the size of spacerto install between the helical driven gear and outer bearing.

Example:Thickness of spacer (Tool CT 41) 12.826

Average Thickness = 12.826.Add 0.25mm to determine spacer/s required =13.076

NOTE: The spacers control the preload adjustment of the drivepinion bearings Always select a spacer as close as possible to thevalue calculated.

Continue with reassembly from procedure 21.


2 Maintenance

Without Service Tool CT 4112. Fit a master spacer X (maximum size 15.155mm) intoposition in the carrier (Fig. 2.28).

13. Using ArvinMeritor service tool CT 45, press the outer bearingcone on the pinion shaft firmly against the master spacer (Fig.2.29) using a press load of 6 - 8 tons.

Fig 2.27Fig 2.28

Fig 2.29

Outer BearingCone

PinionMaster Spacer

X

Wooden BlockPinion Head Support



14. Fit the input flange into position and tighten the pinion nut to atorque value of 1350 - 1670Nm

15. Set a DTI (Dial Test Indicator) against the head of the pinionshaft and set to “0” (Fig. 2.30).

16. Move the pinion shaft and measure the axial movementrecorded on the DTI. Record the measurement Y

17. Using the dimension of the master spacer X and the DTIreading Y calculate the correct spacer value required following thecalculation;

X - Y - 0.08mm (coefficient factor) = Spacer dimension

Example:Master Spacer X = 15.155mmPinion Shaft Axial Movement Y = 0.55mmCoefficient Factor = 0.08mm

15.155 - 0.55 - 0.08 = Correct Spacer Value 14.525mm

NOTE: The spacers control the preload adjustment of the drivepinion bearings Always select a spacer as close as possible to thevalue calculated.

18. Remove the pinion nut and flange.

19. Remove the outer bearing cone and master spacer.

20. Position the calculated spacer identified above to provide thecorrect bearing pinion preload (Fig. 2.31). and continueassembling the carrier


2 Maintenance

Fig 2.30

Fig 2.31

21. Using ArvinMeritor service tool CT 45, press the outer bearingcone of the pinion shaft again, firmly against the spacer/s (Fig.2.32) using a press load of 6 - 8 ton. Rotate the pinion by hand toseat the bearings.

NOTE: If a press is not available procede to point 22 and fit theflange.



22. Fit the flange and tighten the pinion nut to a torque value of1350 - 1670Nm.

NOTE: The flange must be fully seated against the outer pinionbearing before the nut is tighten to the torque specification.

The flange must be held with ArvinMeritor service tool CT 003 totighten the nut and a torque multiplier will be required to achievethe correct torque value of 1350 - 1670 Nm. (Fig. 2.33)


23. Check the bearing preload, it should be 0.5-10Nm (Fig. 2.34).If the preload (torque) of the pinion bearing is not within 0.5 -10Nm, remove the pinion from carrier and follow the appropriateprocedure below:

• To increase preloadinstall a thinner bearing spacer combination.

• To decrease preload install a thicker bearing spacer combination.

2 Maintenance

Fig 2.32

Fig 2.34

Fig 2.33Outer BearingCone

Wooden BlockPinion Head Support

Pinion

Spacer

24. Apply assembly oil to the differential case (Fig 2.35). Install thebearing cones on both sides of the differential case (Figs. 2.36 -2.38).Use a press and ArvinMeritor service tools CT 46 & CT 47. Pressthe cones squarely and firmly on differential cases with a pressforce of 6 - 8 tons.

NOTE: The larger bearing is fitted to the drive gear side of thering gear.


2 Maintenance

Fig 2.35

Fig 2.37

Fig 2.36

Fig 2.38

25. Turn the right hand side adjusting ring by hand and tighteninto the disjoint cap (Fig. 2.39). Fit the RH differential bearing cupover the cone (Fig. 2.40). Fit the cap into position on theDifferential (Fig. 2.41).


26. Safely lift the differential with ring gear, cup, R.H. cap andadjusting ring assembly (Fig. 2.42) using ArvinMeritor service toolCT 52.

2 Maintenance

Fig 2.39

Fig 2.40

Fig 2.41

Fig 2.42

27. While tilting the assembly engage the spigot bearing (Fig.2.43) and install the R.H. cap assembly into locating holes (Fig.2.44).


28. Fit the cap screws and washers that hold the R.H- cap to thecarrier (Fig. 2.45).Tighten all the cap screws by hand four to six turns, then tightento the correct torque value 200Nm+ 90°-105°.

29. Fit the L.H. split cap with a light plastic or rubber mallet (Fig.2.46).

2 Maintenance

Fig 2.43

Fig 2.44

Fig 2.45

Fig 2.46

30. Install the bearing cup and adjusting ring L.H. (Fig. 2. 47) andinstall the cap screws and washers that hold the L.H. Cap to thecarrier.Tighten all the cap screws by hand four to six turns (Fig. 2.48),then tighten to the correct torque value 200 Nm + 90°-105°.

31. Adjust the preload of differential bearings.Using ArvinMeritor service tool CT 12, Tighten the crown wheelside bearing adjuster ring (Fig. 2.49) while turning the croqwnwheel by hand. When a resistance is felt at the crown wheel stoptightening the adjuster ring.

32. Back off the adjuster ring by 2 segments/notches.


33. Set a DTI gauge, diagonaly opposed, against each bearing cap(Fig. 2.50). Set both DTI gauges to “0”.

34. Move to the opposite side of the crown wheel and tighten thebearing adjusting ring until there is movement on the DTI gauges.

NOTE: The bearing cap divergance figure is the combinedreading of both DTI gauges. Example:

Gauge 1 = 0.12mmGauge 2 = 0.17mm

Bearing cap divergance is, 0.12mm + 0.17mm = 0.29mm.

35. Continue to tighten the bearing adjuster ring until a bearingcap divergance value between 0.15mm and 0.33mm is obtained.This will ensure the correct bearing pre-load is achieved.

2 Maintenance

Fig 2.49

Fig 2.50

Fig 2.47

Fig 2.48

2 Maintenance


37. Using ArvinMeritor service tool CT 12 slacken the adjustingring on the drive gear side of the crownwheel and tighten theadjusting ring on the opposite side by the same amount, this willensure the previously measured bearing cap divergance, andtherefore, bearing preload is maintained (Fig. 2.53).

38. Check the gear for run out (Fig. 2.54). If run out exceeds0.20 mm, remove the differential and check for the cause.

36. Check hypoid gear backlash (Fig. 2.51). For new gears thenew backlash should be initially set at 0.38 mm (Fig. 2.52). Theback lash can be altered within the limit of 0.28 - 0.50mm toobtain a better contact position relative to the length of tooth.

NOTE: Check the backlash in a minimum of 3 places.

NOTE: Adjust the backlash by moving the gear only.

Fig 2.51

Fig 2.52

Fig 2.54

Fig 2.53

Tooth contact patterns of hypoid gear set.

With a brush, apply a thin coat of Prussian blue to the drive gearteeth (Fig 2.55). Rotate the pinion and examine the contact marksleft by the pinion teeth on the drive gear teeth.The information provided for Drive Side & Coast side belowindicates correct tooth contact patterns. For detailed informationregarding tooth contact pattern problems, causes and rectificationadvice refer to Section 3 Hypoid Gearing Contact

Drive side (Fig 2.56)Central toward the toe over the face of the gear tooth and in thecentre on the tooth profile.

Coast side (Fig 2.57)Central toward the heel over the face of the gear tooth and in thecentre along the tooth profile.

2 Maintenance


39. After the correct tooth contact patterns have beenestablished, fit the adjusting ring locks and new screws (Figs. 2.58 & 2.59). Tighten the screws to the correct torquevalue 10-12 Nm.

Fig 2.55

Fig 2.56

Fig 2.59

Fig 2.58

Fig 2.57

HEEL

TOE

HEEL

TOE

2 Maintenance

40. When the correct drivr gear tooth pattern and bearing preloadare confirmed remove the pinion nut and flange.

41. Locate a new seal in position (Fig. 2.60). Using a mallet andseal driver CT 01 (Fig 2.61), carefully tap the seal into the carrierbore until the tool is flat against the top of the carrier.


42. Install the input flange onto the drive pinion shaft.

NOTE: The flange must be fully seated against the outer pinionbearing before the nut is tighten to the torque specification.

The flange must be held with ArvinMeritor service tool CT 003 totighten the nut and a torque multiplier will be required to achievethe correct torque value of 1350 - 1670 Nm. (Fig. 2.62)

Fig 2.60

Fig 2.61

Fig 2.62

43. Coat the shift fork slanting face with Molikote Gn Plus grease(Fig. 2.63). Install the shift fork into position in the carrier casewith the protruding boss facing towards the outer bore in thedifferential lock housing (Fig. 2.64).

2 Maintenance


44. Compress the shift shaft spring (65 Kg force) using theArvinMeritor service tool CT 48 (Figs. 2.65 & Fig 2.66).

Fig 2.63

Fig 2.64

Fig 2.65

Fig 2.66

45. While the spring is compressed insert it into the ArvinMeritorservice tool CT 49 and remove from the spring compression toolCT 48 (Figs. 2.67 & Fig. 2.68).


46. Fit the shift shaft spring into the carrier case (Fig. 2.69)tapping the spring out of the assembly tool with a hammer (Fig.2.70).

Fig 2.67

Fig 2.68

Fig 2.69

Fig 2.70

2 Maintenance

2 Maintenance

47. With ArvinMeritor service tool CT 49, or a suitable screwdriverlocate the spring correctly between the two shift shaft bores intothe carrier casting (Fig. 2.71).

48. Whilst holding and tilting the shift fork, place the shift collar inposition in the fork (Fig. 2.72). Ensure there is sufficient roombetween fork and cap (Fig. 2.73)


Fig 2.71

Fig 2.72 Fig 2.73

49. lubricate the cylinder bore with grease Molikote 44.

Apply grease Molikote 44 to the shift shaft (Fig. 2.74) and fit theshift shaft into the cylinder bore (Fig. 2.75).

Fit the 'O' ring, locating correctly in the piston groove.

Generously lubricate the 'O' ring, piston (Fig. 2.76) with greaseMolikote 44 and and carefully insert the piston into the cylinderbore (Fig. 2.77).


Fig 2.74

Fig 2.76

Fig 2.75

Fig 2.77

2 Maintenance

2 Maintenance

50. Fit a new cover gasket (Fig. 2.78) and place the cover airintake in position (Fig. 2.79).

Fit the four capscrews and washers. Tighten the screws to atorque value of 10 -12 Nm.


Installation & Adjustment of the DifferentialLock Sensor Switch

NOTE: The checking and adjustment of differential sensor switchshould be carried out with the complete rear axle installed on thevehicle. However, the switch setting procedure can be carried outin a carrier rig using dummy halfshafts and test meter as shown inFig 2.83.

1. Before fitting the switch, coat the switch point with MoliKoteGN Plus grease.

Apply sealant Loctite 573 to the threads (Fig. 2.80) and carefullyscrew the switch into the differential casing approx. 3 threads (Fig2.81).

Fig 2.78

Fig 2.79

Fig 2.80

Fig 2.81

2. Check the differential lock engagement by applying airpressure air of 6 Kg/cm2 - 6 bar approximately (Fig. 2.82)

3.. As soon as the warning lamp in cab is illuminated (Fig. 2.83),screw the switch in a further one turn of the thread.

4. Tighten the lock nut on the switch to a torque value of 35 - 45Nm.


5. Release the differential lock and ensure in this condition thewarning lamp in the cab is off.

6. Repeat the above operations several times before running onthe road

Fig 2.82

Fig 2.83

2 Maintenance


Hypoid Gear Contact Patterns

pg 40 Hypoid Gear Pattern Tables

3

3 Hypoid Gear Contact Patterns


OPTIMAL CONTACTS

DRIVE SIDE COAST SIDE(CONVEX SIDE RING GEAR) (CONCAVE SIDE RING GEAR)

TOP TOP

HEEL TOE HEEL

BOTTOM BOTTOM

• DRIVE SIDE : Central favouring TOE in length and Central in the profile.• COAST SIDE : Central favouring HEEL in length and Central in the profile.

CONDITION “A”

DRIVE SIDE COAST SIDETOP TOP

HEEL TOE HEEL

BOTTOM BOTTOM

• DRIVE& COAST SIDE : Contact too close to the TOP• DRIVE SIDE : Contact too close to the TOE• COAST SIDE : Contact too close to the HEEL• CORRECTIVE ACTIONS : Add Shims and Increase the Backlash to the maximum

CONDITION “B”TOP TOP

HEEL TOE HEEL

BOTTOM BOTTOM• DRIVE-COAST SIDE : Contact too close to the TOP• CORRECTIVE ACTIONS : Check the Backlash, ADD Shims and re-set the Backlash

CONDITION “C”TOP TOP

HEEL TOE HEEL

BOTTOM BOTTOM• DRIVE-COAST SIDE : Contact too close to the BOTTOM• CORRECTIVE ACTIONS : Check the Backlash, REMOVE Shims and re-set the Backlash.

3 Hypoid Gear Contact Patterns


CONDITION “D”

DRIVE SIDE COAST SIDETOP TOP

HEEL TOE HEEL

BOTTOM BOTTOM

• DRIVE-COAST SIDE : Contact too close to the BOTTOM.• DRIVE SIDE : Contact too close to the HEEL.• COAST SIDE : Contact too close to the TOE.• CORRECTIVE ACTIONS : Remove shims and reduce backlash to the minimum.

CONDITION “E”DRIVE SIDE COAST SIDE

TOP TOP

HEEL TOE HEEL

BOTTOM BOTTOM

• DRIVE SIDE : Contact too close to the HEEL.• COAST SIDE : Contact too close to the TOE.• CORRECTIVE ACTIONS : Reduce the backlash.

CONDITION “F”DRIVE SIDE COAST SIDE

TOP TOP

HEEL TOE HEEL

BOTTOM BOTTOM

• DRIVE SIDE : Contact too close to the TOE.• COAST SIDE : Contact too close to the HEEL.• CORRECTIVE ACTIONS : Increase the backlash.

NOTE: The Contact patterens reported are always on the RING GEAR TEETH.


Pinion Seal Replacement

pg 44 Disassemblypg. 45 Assembly

4

4 Pinion Seal Replacement

The pinion seal replacement detailed below may be carried out withdifferential unit installed on the vehicle.

Disassembly

1. Unscrew the nuts (1) securing the propeller shaft to thedifferential companion flange.

2. Disconnect the propeller shaft (2) and secure it to the chassis.(Fig. 4.1)

3. Block the rotation of the flange (1) using service tool CT03 (2).

4. Using a suitable wrench (3), torque multiplier (4) and service toolCT02 slacken the bevel pinion nut and withdraw the flange (1) (Fig.4.2).

5. With a suitable tool raise the outer edge of the metal inner ring(1) in two opposite points. (Fig. 4.3)

6. Pry with two levers (2) to withdraw the inner ring (1). (Fig. 4.4)

7. Pry with the lever in the direction shown by the arrow to removethe grommet (1). (Fig. 4.5)


Fig 4.1

Fig 4.2

Fig 4.3 Fig 4.4

4 Pinion Seal Replacement


Assembly

1. Thoroughly clean the seal ring seat and remove any trace of dirtor oil.

2. Position a new pinion seal ring (1). Fit service tool CT01 (2).

3. Using an ArvinMeritor service tool pinion nut CT 50 Tighten thepinion nut until the new pinion seal is located fully in the carrier (Fig.4.6)

4. Remove the ArvinMeritor service tool pinion nut CT 50 and ArvinMeritor service tool CT 01 (2). Reassemble the flange andretain with a new pinion nut. Tighten the pinion nut to the torquefigure specified in Section 6 Tightening Torques using a torquewrench and multiplier.

5. Reassemble the propeller shaft and tighten fastening nuts to thetorque specified by the vehicle manufacturer.

Fig 4.6

Fig 4.5


Differential Lock Removal

pg 48 Differential Lock Replacement

5

5 Differential Lock Removal

The procedure detailed below provides a safe and efficient methodfor removing the differential lock components without causingdamage to either the components or carrier.

1. Remove the carrier assembly from the vehicle as described inSection 2 Maintenance and mount securely in a suitable fixture.

2. Remove the four capscrews which secure the differential lockcover to the carrier.

3. Remove the differential lock cover and gasket.

NOTE: Never reuse the existing gasket. Always fit a new gasket onreassembly.

4. Using a copper or plastic faced hammer strike the outer face ofthe differential lock fork. This action should eject the differential lockpiston sufficiently to allow removal from the housing.

5. Remove the differential lock piston.

6. While holding and manipulating the differential lock fork, removethe shift shaft from the cylinder bore.

7. Locate a suitable size diameter socket or sleeve, which is aminimum of 52mm in length, into the cylinder bore so that it abutsagainst the face of the differential lock fork.

8> Refit the differential lock cover and secure in place against thesocket/sleeve with 4 M6 studs, washers and nuts, or M6 bolts (Fig5.1). The studs or bolts must be a minimum of 50mm long.

9. Tighten the nuts/bolts evenly, ensuring the cover is kept squareto the carrier face. This action will compress the differential lock forkand spring sufficiently to allow the differential lock fork to clear thelug of the cylinder on the carrier casting.


10. Carefully withdraw the differential lock fork and spring completefrom the carrier by pulling upwards (Fig 5.2).

11. Remove the differential lock cover, studs or bolts andsocket/sleeve from the carrier.

NOTE: Check that the differential lock spring has not beendamaged or distorted in any way during the removal procedure. Ifthere is a doubt in the suitability of any component for furtherservice, replace with a new ArvinmMeritor service parts.

12. Reassemble the differential lock assembly as described inSection 2 Maintenance.

Fig 5.1

Fig 5.2


Tightening Torque Values & Lubrication

pg 50 Tightening Torque Tablepg 50 Oil Specificationpg 50 Oil Change Intervalspg 50 Oil Capacity6

6 Tightening Torque Values & Lubrication


Description Torque

Nm Degrees Kgm

1 Drive pinion nut 1350-1670 135-167

2 Lock nut sensor switch 35-45 3.5-4.5

3 Cover capscrews 10-12 1.0-1.2

4 Bearing cap, capscrews (torque & angle procedure) 200 90o - 105o 20(torque only) 630 - 846 63 - 84

Carrier to Housing screws (torque & angle procedure 100 105o - 115o

(torque only) 260 - 280

Drain Plug 80 +/- 20

1

2

44

3

Torque Values

Lubrication

Oil Specification Oil CapacityHypoid Gear Oil MS 17X = 12.5 Litres• A.P.I. GL - 5, S.A.E. 80W/140. MIL-2105-D or E• HD ECO 85W140 Mineral GL5

Oil Change Intervals• Standard Applications 120,000 kms• Severe Applications 80,000 kmsor at the Vehicle Manufacturers recommended periods.


Troubleshooting

pg 52 Troubleshooting Chart

7

6 Troubleshooting


Fault

1. Wheel hub noise andpossible overheating

2. Anomalous knocks from thedifferential during acceleration/ deceleration stages

3. Noise when travelling

4. Oil leakages

Possible causes

The oil used is not of the type specified by themanufacturer

Low oil level

Incorrect backlash between drive gear teeth

Gears damaged

Bearings worn or maladjusted

Incorrect use of retarder/exhaust brake

Driving wheel loose on hub

Differential unit splined sections worn

Low oil level in axle housing

Teeth and/or bearings worn or damaged

Bearings maladjusted or damaged

Excessively high oil level in axle housing

Breather blocked

Seal rings damaged

Screws/nuts loose

Seal between axle housing and differential unitdamaged

Remedy

Drain oil from housing and fill with new oil of the specifiedtype

Top up oil level in housing

Remove bevel drive gear pair. Trace cause for possible geardamage. Adjust as requiredReplace defective components

Replace defective components

Check retarder/exhaust brake efficiency and setting. Look forpossible damage to bevel drive gear pair and bearings

Check wheel nuts at regular intervals and tighten, as required

Replace worn components

Top up oil level

Replace damaged components

Adjust bearings and replace, as required

Check oil level

Clear/replace breather

Replace damaged seal rings

Clean threads, coat with sealant if necessary, and tighten tothe specified torque

Remove differential unit, check and clean all sealing surfacesand coat parts concerned with sealant, as required

The following chart shows the most common faults occurring to a differential unit.

For further information contact

ArvinMeritor HVS Limited

Commercial Vehicle Systems

Grange Road, Cwmbran

South Wales NP44 3XU - UK

Tel: +44 (0) 1633 834238

Fax: +44 (0) 1633 834191

www.arvinmeritor.com/tech library

Copyright 2007

ArvinMeritor Automotive

All rights Reserved

Publication MM-0700EN

Descriptions and specifications were in effect at the

time of this publication and are subject to change

without notice or liability. Meritor reserve the right to

make design improvements, change or discontinue

parts at any time

mm-0700 draft 9 feb 07.qxp

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