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1 Exploded ViewsSingle-Reduction Forward Differential Carrier1 Exploded 1Nut — Input Yoke35Ring Gear and Drive Pinion70Shift Shaft — Main Differential Lock1AWasher — Input Yoke36Inner Bearing Cone — Drive Pinion70A2Input Yoke37Inner Bearing Cup — Drive PinionShift Shaft — Main Differential Lock —Current Design3Deflector38Shims71Piston — Main Differential Lock71APiston — Main Differential Lock —Current Design72O-Ring — Piston72AO-Ring — Piston — Current Design73DCDL Cylinder — Shift Shaft73ADCDL Cylinder — Shift Shaft — CurrentScrew-In DCDL Design74Copper Gasket — Cover (160 Series)75Capscrew — Manual Engaging75ACapscrew — Manual Engaging — CurrentDesign76Cover — Main Differential Lock (EarlyDesign)4Capscrew — Cage-to-Carrier39Inner Spacer5Washer — Cage-to-Carrier40Helical Driven Gear6Oil Seal — Triple-Lip (Main) Seal41Outer Spacer6APOSE Seal42Outer Bearing Cup — Drive Pinion7Input Bearing Cage43Outer Bearing Cone — Drive Pinion8Shims44Washer — Drive Pinion9O-Ring — Input Bearing Cage45Nut — Drive Pinion10Bearing Cup — Input Shaft46Cover — Drive Pinion11Bearing Cone — Input Shaft47Washer — Drive Pinion Cover12Oil Baffle (Units Without Oil Pump)48Capscrew — Drive Pinion Cover13Washer — Oil Baffle49Bearing Adjusting Ring14Capscrew — Oil Baffle50Cup — Main Differential Bearing15Input Shaft51Cone — Main Differential Bearing77Plug — Manual Engaging (Early Design)16Thrust Washer — Helical Drive Gear52Capscrew — Main Differential CaseHalves78Washer — Manual Engaging Capscrew79Capscrew — Cover (Early Design)Inter-Axle Differential Case Assembly53Washer — Main Differential Case Halves80Washer — Cover (Early Design)Snap Ring — Inter-Axle Differential Case54Main Differential Case Assembly81Shift Collar — Main Differential LockClutch Collar — Inter-Axle DifferentialCase55Bolt — Ring Gear (145 and 160 Series)82Shift Fork — Main Differential Lock56Washer — Differential Bearing Cap82A21Rear Side Gear57Capscrew — Differential Bearing CapShift Fork — Main Differential Lock —Current Design22Shift Fork5883Roll Pin — Shift Fork (Early Design)23Bearing Cone — Rear Side GearRoll Pin, Cotter Pin or Capscrew —Differential Bearing Cap84Oil Filter Shield59Thrust Washer — Main Differential SideGear85Plug — Oil Pressure Relief Valve86Washer — Oil Pressure Relief Valve60Side Gear — Main Differential87Spring — Oil Pressure Relief Valve61Spider — Main Differential88Oil Pressure Relief Valve62Pinion Gear — Main Differential8963Thrust Washer — Main DifferentialDowel — Input Cage to Oil Pump (EarlyDesign)63ANoSPIN Main Differential *90O-Ring — Oil Pump64Washer — Ring Gear (145 and 160Series)91Oil Pump92Washer — Oil Pump93Capscrew — Oil Pump94Oil Filter95Adapter — Oil Filter96Oil Screen and Plug Assembly17181920Helical Drive Gear24Bearing Cup — Rear Side Gear25Adjusting Screw — Shift Shaft26Jam Nut — Adjusting Screw27Spring — Shift Shaft28Shift Shaft and Piston28A“E” Clip (Reverse Shift IAD Only)29Air Shift Chamber Assembly — Bolt-OnIAD29AAir Shift Chamber Assembly — Screw-InIAD65Nut — Ring Gear (145 and 160 Series)30Capscrew — Air Shift Chamber Assembly66Sensor Switch — Main Differential Lock31Differential Carrier and Caps6732Washer — Differential Carrier-to-AxleHousingLocknut — Main Differential Lock SensorSwitch (Early Design)68Spring — Main Differential Lock33Nut — Differential Carrier-to-Axle Housing68A34Capscrew — Differential Carrier-to-AxleHousingSpring — Main Differential Lock —Current Design69Lock Pin — Spring Retaining (Early Design)* NoSPIN is a registered trademark of Tractech,a division of Dyneer Corp.ArvinMeritor Maintenance Manual 5L (Revised 12-10)01

1 Exploded ViewsFigure 1.188INPUT WITHOIL PUMP ASTANDARD DIFFERENTIALCARRIER WITHOUT DIFFERENTIALLOCK AND WITHOUT OIL PUMP292625303127282472 A2319181771 A28 A29 A16213220342233 323582 A3637394841L.H. SIDE3840424347 4645314471837482808169 70949572OIL PUMPPARTS6675 A6770 A68 A2ArvinMeritor Maintenance Manual 5L (Revised 12-10)7975689607372 A71 A73 A76 78DIFFERENTIALLOCK PARTS771003392a

1 Exploded ViewsFigure .H. SIDE605463 A35CURRENT DCDLEARLY DESIGN DCDL687168 A7475 A8070 A7067 6972 A7271 A73 A7379757678 77OIL PUMPNoSPIN ASSEMBLY919293901563 A54 MAIN DIFFERENTIALCASE ASSEMBLYPLAINCASE HALFGEARCASE HALF1002701cArvinMeritor Maintenance Manual 5L (Revised 12-10)3

2 IntroductionDescriptionAxle Models Covered in This ManualForward Tandem AxleTandem Models2 IntroductionThe inter-axle differential is located behind the helical gear on theinput shaft. The forward side gear of the inter-axle differential is partof the upper helical gear hub. The thru-shaft is splined to the rearside gear of the inter-axle differential. Figure 143RT-44-145PRT-50-160PRT-40-145RT-46-16H EHRT-52-160PRZ-186RZ-188Figure 2.1INPUTSHAFTHELICALOIL ATridem ModelsRZ-166DRIVEPINIONRINGGEAR1002702cFigure 2.1The Meritor 140, 145 and 160 forward tandem axles use asingle-reduction, thru-drive carrier. The drive gearing is atwo-helical gear train and a hypoid ring gear and pinion. Bevel gearsare used in the main differential and the inter-axle differential.Figure 2.1 and Figure 2.2.NOTE: For service procedures on rear carriers, refer toMaintenance Manual 5, Single-Reduction Differential Carriers, formodels preceding RS-, RT- and RF-Series, and Maintenance Manual5A, Single-Reduction Differential Carriers, for MX-, RS-, RT- andRF-Series. To obtain these publications, refer to the Service Notespage on the front inside cover of this manual.Optional Pressurized Lubrication SystemThe forward axles can be equipped with an optional pressurizedlubrication system. This filtered system has an oil pump driven bythe input shaft. The pump circulates lubricant to the journals in theforward and rear input shaft bearings and directly to the inter-axledifferential.Figure 2.2RT-160 SERIES SHOWNNotch on inter-axledifferential case.Notches are providedfor clearance inassembly anddisassembly.HELICALDRIVENGEARFigure 2.2Optional Driver-Controlled Main DifferentialLock (DCDL)Both the forward and rear axles can be equipped with an optionaldriver-controlled main differential lock (DCDL). The differential lockis operated by an air-actuated shift unit located on the forwardaxle carrier.앫 When the differential lock is activated, the shift collar movesalong the splines of the axle shaft toward the differential case.1002703c앫 When the collar splines engage with the splines on thedifferential case, the axle shaft and the differential assembly locktogether.앫 When the carrier operates with the DCDL in the locked position,there is no differential action between the wheels.앫 When the carrier is operated in the unlocked position, there isnormal differential action between the wheels at all times.04ArvinMeritor Maintenance Manual 5L (Revised 12-10)

2 IntroductionInter-Axle Main Differential (IAD)Figure 2.3AXLE IDENTIFICATION TAG INFORMATIONThe Meritor inter-axle differential (IAD) is a driver-controlled,air-actuated traction device. The IAD allows for speed differencesbetween the forward and rear axles in a tandem while also providingequal pulling power from each axle of the tandem. By activating theIAD switch located in the vehicle dash, improved traction is providedfor each axle.Model No. . . . . . . . . . . . . . . . . . . .Customer No. . . . . . . . . . . . . . . . .Serial No. . . . . . . . .Ratio . . . . . . . . . . . .The inter-axle differential is also known as a power divider or thirddifferential.Plant . . . . . . . .IDENTIFICATION TAGLOCATION OF THE IDENTIFICATION TAG, OR STAMPNUMBER, FOR THE AXLES. LOCATION ISDETERMINED FROM THE LEFT DRIVER SIDELOOKING TOWARD THE FRONT OF THE VEHICLE.AStall-Testing Can Damage a Drive AxleStall-testing is a procedure used to troubleshoot transmissions,evaluate vehicle performance, and test the service and park brakes.During stall-testing, or any similar procedure, the drive axle inputreceives multiplied torque, which can exceed the specified torquerating. Excessive torque can damage a drive axle, which will affectaxle performance and component life. A drive axle damaged bystall-testing will void Meritor’s warranty.BA — FRONT ENGINE DRIVE — RIGHT REAR, NEXTTO COVERB — REAR ENGINE DRIVE — LEFT OR RIGHT REAR,NEXT TO DRIVE UNIT1002704cCall ArvinMeritor’s Customer Service Center at 800-535-5560 ifyou have questions regarding stall-testing.Figure 2.3Use of Traction ChainsFigure 2.4Meritor recommends that if you are using traction chains, youshould install chains on both tires on each side of all drive axles onthe vehicle.IdentificationAXLE HOUSINGIDENTIFICATION TAGModel NumberCARRIER PART NO.CUSTOMER NO.SERIAL NO.RATIO.l No .de r NoMo mesto .Cul NoriaSetioRaAn identification tag is riveted on the axle housing or on thedifferential carrier. Figure 2.3 and Figure 2.4. Use the modelnumber and the ratio number marked on the identification tag andthe number on the carrier to order replacement parts.ntPlateDaModel No.Customer No.Serial No.RatioAXLEIDENTIFICATION TAGPlantDateCARRIER PART NO.CUSTOMER NO.SERIAL NO.RATIOCARRIERIDENTIFICATION TAG4000625aFigure 2.4ArvinMeritor Maintenance Manual 5L (Revised 12-10)5

2 IntroductionRefer to Figure 2.5 for an explanation of the model number.Figure 2.5CARRIER MODEL TAG NUMBER INFORMATIONM T - 40 - 1 4 XAxle Design Variation: Indicatesaxle design level or variation,(e.g., RS-23-161 has a thickerwall housing than RS-23-160).For information, refer to the Billof Materials for that specificaxle model.MeritorCarrier Type: Carrier size. Larger numbersindicate a higher GCW rated Carrier; i.e.,larger ring gear, etc.Gearing Type:1 Single SpeedNominal Axle Load Rating (GAWR): In thousands of pounds.Individual forward and rear axles of a tandem set (D, N, P) are ratedas single axles. A tandem set (T) is rated as the combination of thetwo axles.Axle TypeD Forward-Rear Axle of a Drive Tandem with Inter-Axle DifferentialN Forward-Rear Axle of a Drive Tandem without Inter-Axle DifferentialP Forward-Rear Axle of a Drive Tandem with Inter-Axle Differential and PumpT Tandem Drive Axle SetFigure 2.56ArvinMeritor Maintenance Manual 5L (Revised 12-10)1002705e

3 Removal and DisassemblyHazard Alert Messages3 Removal and DisassemblyRead and observe all Warning and Caution hazard alert messages inthis publication. They provide information that can help preventserious personal injury, damage to components, or both.WARNINGToolPart NumberManufacturerAxle Shaft RemoverK-1280Kiene DieselAccessories, Inc.Axle Stud Cone Plier7077SPX OTCBrass Drift MethodTo prevent serious eye injury, always wear safe eye protectionwhen you perform vehicle maintenance or service.Use a brass or synthetic mallet for assembly and disassemblyprocedures. Do not hit steel parts with a steel hammer. Piecesof a part can break off. Serious personal injury and damage tocomponents can result.Observe all warnings and cautions provided by the pressmanufacturer to avoid damage to components and seriouspersonal injury.WARNINGDo not strike the round driving lugs on the flange of an axleshaft. Pieces can break off and cause serious personal injury.1.Hold a 1-1/2-inch diameter brass drift or brass hammeragainst the center of the axle shaft, inside the round drivinglugs. Figure 3.1.Figure 3.1BRASSHAMMERRemovalDRIVINGLUGSAxle ShaftsBefore the axle shafts and differential carrier can be removed orinstalled, the driver-controlled differential lock (DCDL), if equipped,must be shifted into and held in the locked or engaged position. Thelocked position gives enough clearance between the shift collar andthe axle housing to permit the removal or installation of the axleshafts and carrier. Refer to Section 6 for service information on theDCDL. If the drive axle is not equipped with DCDL, continue on withaxle shaft removal in this section.Axle Shaft Removal MethodsUse Special Tools Recommended by MeritorTo help prevent serious personal injury and damage to componentswhen you remove the axle shaft from the housing, Meritorrecommends that you use the following tools in the table below.Refer to the Service Notes page at the front inside cover of thismanual for information on how to contact the manufacturers toobtain the tools.1002707bFigure 3.12.Strike the end of the drift with a large hammer, five to sixpounds, and the axle shaft and tapered dowels will loosen.3.Mark each axle shaft before it is removed from the axleassembly.4.Remove the tapered dowels and separate the axle shafts fromthe main axle hub assembly. Figure 3.2.앫 If the tools are not available when you remove the axleshaft: Follow procedures for using the Brass Drift Method or theAir Vibration Method.ArvinMeritor Maintenance Manual 5L (Revised 12-10)7

3 Removal and DisassemblyFigure 3.2Figure LESHAFT ORFLANGEROUND HAMMERBIT BETWEEN HUBSTUDSSTUDSHAFTHUBAXLE1002708b1002987cFigure 3.2Figure 3.35.Install a cover over the open end of each axle assembly hubwhere an axle shaft was removed.3.Mark each axle shaft before it is removed from the axleassembly.4.Remove the tapered dowels and separate the axle shaft fromthe main axle hub assembly. Figure 3.2.Air Hammer Vibration MethodWARNINGWear safe eye protection when using an air hammer. Whenusing power tools, axle components can loosen and break offcausing serious personal injury.Axle Shafts from the Axle HousingWARNINGCAUTIONDo not use a chisel or wedge to loosen the axle shaft andtapered dowels. Using a chisel or wedge can result in damageto the axle shaft, the gasket and seal, and the axle hub.1.2.8Use a round hammer bit and an air hammer to loosen thetapered dowels and axle shaft.Place the round hammer bit against the axle shaft or flangebetween the hub studs. Operate the air hammer at alternatelocations between the studs to loosen the tapered dowels andaxle shaft from the hub. Figure 3.3.ArvinMeritor Maintenance Manual 5L (Revised 12-10)Park the vehicle on a level surface. Block the wheels toprevent the vehicle from moving. Support the vehicle withsafety stands. Do not work under a vehicle supported only byjacks. Jacks can slip or fall over. Serious personal injury anddamage to components can result.1.Park the vehicle on a level surface. Block the wheels to preventthe vehicle from moving. Set the parking brake.2.Use a jack to raise the vehicle so that the wheels to be servicedare off the ground. Support the vehicle with safety stands.3.Remove the oil drain plug from the bottom of the axle housing.Drain the axle lubricant from the housing assembly.4.For axles with an oil pump, remove the oil filter shield from theinput bearing cage.5.Use a filter strap wrench to remove the oil filter. Be careful thatthe oil inside does not spill when removing the filter. Discardthe filter. Figure 3.4.

3 Removal and DisassemblyFigure 3.5Figure 3.41EASY SERVICETMOILFILTER29OIL FILTERADAPTER3485671002706b10WING SERIESPERMALUBETMFigure 3.46.1112Inspect the oil filter adapter threads.1413앫 If the adapter threads are damaged: Remove andreplace the oil filter adapter.7.FULL-ROUNDOn an axle with a driver-controlled main differential lock, shiftthe lock into and hold the lock in the locked or engagedposition. The locked position provides enough clearancebetween the shift collar and the axle housing for carrierremoval. Refer to Section 6.1516An alternate method to obtain clearance is to remove the coverof the air shift unit from the differential carrier. Remove thepiston. Remove the shift shaft and spring from the fork. Thefork and the clutch collar will fall into the carrier and the carriercan be removed. Remove the fork and the clutch collar afterthe carrier is removed.8.191718RPL SERIES,PERMALUBETM252021Disconnect the driveline universal joint from the pinion inputyoke or flange on the carrier. Figure 3.5.22249.Remove the capscrews and washers or stud nuts and washers,if equipped, from the flanges of both axle shafts.10. Loosen the tapered dowels, if equipped, in the axle flanges ofboth axle shafts using one of the following methods. Refer tothe procedures in this section.2312345678910111213FULL-ROUND BEARING CUPSEND YOKEYOKE SADDLEWELD YOKEBEARING STRAPCAPSCREWSEASY SERVICE BEARING CUPSU-JOINT CROSSSLIP YOKECAPSCREWSEND YOKEWELD YOKESLIP YOKE1415161718192021222324251002984cU-JOINT CROSSCAPSCREWSEND YOKEWELD YOKESLIP YOKEU-JOINT CROSSCAPSCREWSEND YOKESLIP YOKETUBINGU-JOINT CROSSWELD YOKEFigure 3.5ArvinMeritor Maintenance Manual 5L (Revised 12-10)09

3 Removal and DisassemblyThru-Shaft5.Remove the thru-shaft bearing cage capscrews and washers.1.6.Pull the bearing cage, bearings and shaft assembly from theaxle housing. If necessary, loosen the cage from the housingwith a soft mallet. Figure 3.8.Disconnect the forward and rear drive shafts.CAUTIONAlways use a flange or yoke bar during removal and installationof the flange yoke nut to prevent damage to the gearing.2.Figure 3.8THRU-SHAFT ANDBEARING CAGE ASSEMBLYAttach a flange bar to the flange or place a yoke bar over theinput or output yoke to hold the yoke or flange while youremove the pinion nut. Figure 3.6. Refer to Section 10 tomake a yoke bar.Figure 3.61002713aFigure 3.8Differential Carrier from the Axle HousingYOKE BAR1003451b1.Place a hydraulic roller jack under the differential carrier tosupport the assembly. Figure 3.9.Figure 3.6Figure 3.93.Disconnect the air lines at the inter-axle differential shift unit.4.Remove the thru-shaft nut, washer and yoke or flange. Use apuller tool to remove the yoke or flange from the shaft.Figure 3.7.TOP TWOFASTENERSFigure 3.7REMOVINGTHE FLANGEREMOVINGTHE YOKEROLLERJACK1002714cFigure 3.91002712dFigure 3.710ArvinMeritor Maintenance Manual 5L (Revised 12-10)2.Remove all but the top two carrier-to-housing capscrews orstud nuts and washers. Figure 3.9.

3 Removal and Disassembly3.Loosen, but do not remove, the top two carrier-to-housingfasteners. The fasteners will hold the carrier in the housing.Disassembly4.Loosen the differential carrier in the axle housing. Use a plasticmallet to hit the carrier mounting flange at several points.Thru-Shaft and Output Bearing CageAssembly5.After the carrier is loosened, remove the top two stud nuts andwashers that hold the assembly in the axle housing.1.CAUTIONFigure 3.11When using a pry bar, be careful not to damage the carrier orhousing flange. Damage to these surfaces will cause oil leaks.6.7.Remove and discard the original oil seal. Use a new triple-lip ormain oil seal when the carrier is assembled. Figure 3.11.THRU-SHAFTBEARINGSNAPASSEMBLIES RINGUse the hydraulic roller jack to remove the carrier from the axlehousing. Use a pry bar that has a round end to help remove thecarrier from the housing.OUTPUTYOKEOn axles with a driver-controlled main differential lock, if airpressure is used to shift the differential to the locked orengaged position, release the air pressure. Disconnect the airhose from the shift unit.SPACEROILSEAL1002716bFigure 3.11NOTE: A carrier stand is available from SPX Kent-Moore. Refer tothe Service Notes page on the front inside cover of this manual toobtain the stand.NOTE: If you replace either the bearing cup or the cone, replaceboth parts in a fully-matched set from the same manufacturer.8.2.Remove the external snap ring or yoke-to-cone spacer fromthe thru-shaft.3.Remove the internal snap ring that holds the bearing cup in theoutput cage. Figure 3.12.Use a lifting tool to lift the differential carrier by the input yokeor flange and place the assembly in a repair stand. Do not liftby hand. Refer to Section 10 to make a carrier repair stand.Figure 3.10.Figure 3.10Figure 3.12BEARINGCAGESNAPRINGTHRU-SHAFTEND VIEW1002715c1002717bFigure 3.10Figure 3.12ArvinMeritor Maintenance Manual 5L (Revised 12-10)11

3 Removal and DisassemblyNOTE: When you press the thru-shaft from the cage, the inner cupremains in the cage. The outer cup is removed with the thru-shaftand the cones.3.Press the thru-shaft through the bearing cones. Discard thebearing cones.Bearing Puller Method4.If necessary, remove the thru-shaft and the bearing cones asan assembly from the output bearing cage.1.Place a used bearing cup on the inner bearing cone.A.Place the thru-shaft and the output bearing cage in apress. Figure 3.13.2.Install a bearing puller tool onto the thru-shaft. Figure 3.15.The bearing cup supports the thru-shaft.B.Press the thru-shaft and cones from the bearing cage.C.Remove the outer cup from the thru-shaft.Figure 3.15Figure 3.13PRESSUSED BEARINGCUP1002720b1002718b1002718bFigure 3.135.Use a press or a bearing puller to remove the bearing conesfrom the thru-shaft. Refer to the procedure in this section.Figure 3.153.Remove the bearing cones from the thru-shaft. Discard thebearing cones.4.If necessary, use a brass drift and hammer to carefully tap theinner cup from the cage. Discard the cup. Figure 3.16.RemovalFigure 3.16Bearing Cone from the Thru-ShaftPress Method1.Place a used bearing cup on the inner bearing cone.2.Place the thru-shaft into a press. Figure 3.14. The usedbearing cup supports the thru-shaft.Figure 3.14PRESS1002721bUSED BEARINGCUP1002719c1002719cFigure 3.14012ArvinMeritor Maintenance Manual 5L (Revised 12-10)Figure 3.16

3 Removal and DisassemblyMeasure Ring Gear BacklashFigure 3.18Before the carrier is disassembled, use a dial indicator to measureand record ring gear backlash at three locations on the ring gear.This will help you to correctly reassemble the ring gear anddrive pinion.1.Rotate the carrier in the stand to access the ring gear teeth.2.Install a dial indicator onto the flange of the carrier. Place thetip of the indicator against the drive side of a ring gear tooth.Adjust the dial indicator to ZERO. Figure 3.17.PINIONCOVER1002723bFigure 3.18Figure 3.17DIALINDICATOR3.Use the correct tool to hold the input yoke or flange. Loosen,but do not remove, the drive pinion nut. Figure 3.19.Figure 3.191002722cFigure 3.173.4.Read the dial indicator while you slightly rotate the ring gear inboth directions. When you rotate the ring gear to measure thebacklash, the drive pinion must not move. Record the readingon the dial indicator.Repeat the procedure at two more locations on the ring gear.앫 If the

Assembly) and with Inter-Axle Differential (IAD) 114 Forward Tandem Axle, without Driver-Controlled Main Differential Lock (DCDL), with Inter-Axle Differential (IAD) 116 Section 12: Diagnostics Troubleshooting . 28A “E” Clip (Reverse Shift IAD Only) 29 Air Shift Chamber Assembly — Bolt-On IAD 29A Air