Meritor RS 120 Maintenance Manual Download

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SINGLE REDUCTION AXLE

RS 120 - Rear Axle (NGIT)

FIELD MAINTENANCE MANUAL

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Meritor HVS (India) Limited,

Plot No: 36, Hootagalli Industrial Area,

Off Hunsur Road, Mysore-570 018

Ph: +91 821 2403235 Fax: +91 821 2403234

Phone: +91 821 2403235 fas91 8212403234

Summary of Contents for RS 120

Page 1: ...LD MAINTENANCE MANUAL _________________________________________ ________ Meritor HVS India Limited Plot No 36 Hootagalli Industrial Area Off Hunsur Road Mysore 570 018 Ph 91 821 2403235 Fax 91 821 2403234 Phone 91 821 2403235 fascimile 91 8212403234 ...

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Page 3: ...Section 1 Introduction 3 ...

Page 4: ...G 1 Raise the rear end of the vehicle put on jack stands Figure1 Jack Stands Figure 1 2 Disconnect the propeller Shaft from input flange Figure 2 remove drain plug and drain differential oil Disconnect the vehicle air line from the differential lock actuator assy Figure 2 4 ...

Page 5: ...rews B fastening axle drive shaft to wheel hub Figure 3 Figure 3 Remove axle shafts using extraction holes Remove all the carrier mounting fasteners Differential Carrier Remove the carrier from the housing Mount the carrier on a repair stand Figure 4 Driving lugs Repair Stand Figure 4 5 ...

Page 6: ...SASSEMBLY OF DIFFERENTIAL If the same gear set is to be reused record the backlash before disassembly Figure 5 Figure 5 Bearing Cap Carrier Leg 1 Make match marks on one Carrier leg and bearing cap Figure 6 Match Marks Figure 6 6 ...

Page 7: ...Section 2 Disassembly 3 Remove cotter pin using a small drift and hammer Figure 7 Removing Cotter Key Figure 7 Remove cap screw washers and lock plate Figure 8 Figure 8 7 ...

Page 8: ...Section 2 Disassembly 4 Remove cap screws and washers of bearing caps Figure 9 Remove bearing adjusting rings Bearing Cap Figure 9 Figure 10 5 Lift the differential case ring gear assembly Figure 10 8 ...

Page 9: ...e match marks on the diff case halves Figure 11 Match Marks Match Marks Figure 11 7 Remove the diff case bolts separate case halves Remove spider pinions side gears and thrust washers Figure 12 Trust Washer Side Gear Figure 12 9 ...

Page 10: ...e ring gear from diff case using a press Figure 13 Press Plate Figure 13 Puller 9 Remove the bearings from diff cases using bearing puller press Figure 14 Press Figure 14 10 Fasten a flange bar to the companion flange Remove pinion nut and washer Figure 15 Figure 15 Flange Bar 10 ...

Page 11: ...rews and washers of bearing Cage SHIMS DRIVE PINION AND BEARING CAGE Remove bearing Cage and shims Measure and note down the total thickness of removed shims Figure 16 Drive Pinion Press Oil Seal Bearing Cage Support Support 12 Remove drive pinion from bearing Cage using a press Figure 17 Figure 17 11 ...

Page 12: ...rom the cage using a small drift and hammer Pinion Bearing cage Figure 18 Drive Pinion Inner Bearing Cone 14 Remove the inner bearing cone using the split puller and press Figure 19 Bearing Support Figure 19 Bearing Puller 15 Remove the snap ring Remove the spigot bearing using the puller Figure 20 Figure 20 12 ...

Page 13: ... required See the torque chart T NOTE There is no drying time required for Dri Loc fasteners Install Old Dri Loc Fasteners Using Meritor Liquid Adhesive 2297 C 3747 or Loctite 277 Figure 21 1 Clean the oil and dirt from threaded holes There is no special cleaning required and it is not necessary to remove the old Dri Loc adhesive from the threads 2 Apply four or five drops of Meritor Liquid Adhesi...

Page 14: ... adhesive to the threaded hole Follow the procedure for installing old Dri Loc fasteners Application of Silicone Gasket Material NOTE The following silicone gasket products can be used on Meritor components 1 General Electric No RTV 1473 black 2 From Meritor Automotive Inc 0 4 kg tube Part No 1199 Q 2981 Remove Dri Loc Fasteners If it is difficult to remove Dri Loc Fasteners from components the St...

Page 15: ...ed a 125 Inch diameter bead Too much gasket material can block lubrication passages 5 Assemble the components immediately to permit the silicone gasket material to compress evenly between the parts Tighten fasteners to the required torque value for that size fastener There is no special procedure or torque value required See Torque Chart 6 Wait 20 minutes before the assembly is filled with lubrica...

Page 16: ...r diameter NOTE A 5 37 gear set has a 5 tooth drive pinion and a 37 tooth ring gear B C Location on Drive Pinion End at splines Location on Ring Gear Front face or outer diameter 3 Gear Set Match Number Meritor drive pinions and ring gears are available only as matched sets Both gears of a set have the same match number A Example of a gear set match number 07 B 1234 B C NOTE A gear set match numbe...

Page 17: ... number is used when you adjust the depth of the pinion In the carrier See the procedure for adjusting the shim pack thickness under the pinion cage A B Examples of pinion cone variation numbers PC 3 PC 5 2 1 01 mm or 0 02mm Location on Gear Set End of pinion gear head or outer diameter of ring gear Figure 24 Figure 24 PINION CONE VARIATION NUMBER 17 ...

Page 18: ...3 To prevent corrosion DO NOT clean ground or polished parts in a hot solution tank water steam or alkaline solutions WARNING Be careful when using hot solution tanks and alkaline solutions Follow thealkalinemanufacturer s Instructions for safe use to prevent injury 4 Parts must be washed with water until the alkaline solution is removed Dry Parts That Have Been Cleaned 1 Parts must be dried immed...

Page 19: ... assembly If any of the following conditions exist the bearing MUST be replaced Figure 26 CRACK WEAR GROOVE WORN RADIUS C A visible roller groove in the cup or cone inner race surfaces The groove can be seen at the small or large diameter end of both parts Figure25 D Deep cracks or breaks in the cup cone inner race or roller surfaces Figure 25 Figure 27 WORN SURFACE A The center of large diameter ...

Page 20: ...lines of both differential side gears F Damage on rollers and on surfaces of the cup and cone inner race that touch the rollers Figure 28 Figure 29 SPALLING FLAKING E Teeth and bore of all differential pinions CAUTION Always replace thrust washers differential side gears and pinions in sets A higher stress on parts and an early failure of the assembly will occur if a new part is used with parts th...

Page 21: ...an and repair threads of fasteners and holes Use a die or tap of the correct size or a fine file for this purpose Repair Axle By Welding 1 Meritor Automotive Inc will permit repairing drive axle assemblies by welding ONLY in the following areas A Cover welds B Snorkel welds C Housing seam welds between the suspension attaching brackets CAUTION Welding can be used when the crack or damaged area is ...

Page 22: ...eated at 70S0 F 3710 C for one hour before welding 2 Welding Procedure A Drain the lubricant from the axle assembly B Remove the axle shafts and differential carrier from the axle housing WARNING Be careful when using a cleaning solvent Followthesolvent manufacturer s Instructions for safe use to prevent Injury C Clean the damaged area inside and outside the housing Cleaning solvent can be used D ...

Page 23: ...in seam welds MUST be ground out to 70 of the wall thickness The wall thickness can be measured at the carrier opening of housing 4 Clean the new weld area Carefully remove all rough weld material 5 Install the differential carrier and axle shafts 6 Fill the axle assembly with the correct amount of lubricant See Meritor Maintenance Manual for information on lubricants 23 ...

Page 24: ...g gear and drive pinion are same Location of marks are as shown in Figure 30 A Tooth combination number B Set number C Part number D Pinion cone variation number PRESS 1 Press inner and outer bearing cups into bearing cage using correct sleeves Figure 28 Sleeve A B C Figure 30 A B A C Cage Bearing Cup Figure 31 24 ...

Page 25: ...embly Inner Bearing Cone Sleeve 2 Press the inner bearing cone on the pinion till it sits firmly Figure 32 Figure 32 3 Press the spigot bearing on the drive pinion Figure 33 Figure 33 Press Sleeve Spigot Bearing 25 ...

Page 26: ...e 34 Outer Bearing Cone Bearing Spacer 5 Position the bearing cage over inner bearing cone Apply axle lubricant on bearings Install the bearing spacer Press the outer bearings cone on the pinion till it sits firmly on the spacer Figure 35 Bearing Cage Drive Pinion Figure 35 Inner Bearing Cone 26 ...

Page 27: ...e is held wind a cord around the cage with the spring scale Figure 36 if the press is not available install companion flange and tighten pinion nut to the torque of 300 400 ft lbs Pull the cord on horizontal line as the cage rotates read the scale Spring scale should read between 2 to 5 kgs If The scale reading is not within the specification To increase preload reduce bearing spacer thickness To ...

Page 28: ...inion Note pinion cone variation number etched on removed gear If this no is a plus subtract the no from old shim pack thickness Or If it is a minus add the no to old shim pack thickness The value arrived as above is the thickness of standard shim pack If pinion cone variation no of new gear set is minus subtract the no from standard pack arrived as above Or If it is plus add to standard pack thic...

Page 29: ...ack Thickness 3 Old Shim Pack Thickness Old PC Number PC 2 Standard Shim Pack Thickness New PC Number PC 5 New Shim Pack Thickness 4 Old Shim Pack Thickness Old PC Number PC 2 Standard Shim Pack Thickness New PC Number PC 5 New Shim Pack Thickness Inches 0 030 0 002 0 028 0 005 0 0330 0 030 0 002 0 032 0 005 0 037 0 030 0 002 0 028 0 005 0 023 0 030 0 002 0 032 0 005 0 027 mm 0 760 0 050 0 710 0 1...

Page 30: ...nge half Immediately aligning mounting holes Figure 38 12 Install mounting bolts and nuts Tighten the nuts to the torque of 70 80 ft lbs Figure 38 Ring Gear Flange Case Half Bolt Head against gear Figure 39 13 Install the bearing cones on both Diff cases 14 Install spider side gear diff pinions and thrust washers into flange half Install plain half aligning match marks Figure 39 Torque tighten the...

Page 31: ...rs Figure 40 Recommended torque is 5 20 ft lbs If torque is more check case halves spider diff gears thrust washers Replace the parts as necessary Figure 40 Read Torque value Adhesive Bearing Cap Carrier Leg 16 Apply adhesive to bearing bores Figure 41 Figure 41 31 ...

Page 32: ...adj rings and hand tighten till these touches the diff bearing Figure 42 Figure 42 Adjusting Ring Leg 18 Install the bearing caps aligning the match marks figure 43 Tighten the bearing cap bolts until the bolt head sits on the bearing caps Bearing Cap Match Marks Figure 43 32 ...

Page 33: ...that that the plunger is against the back face of the ring gear Figure 44 DIAL INIDICATOR Figure 44 Pry bar Must Not Touch Bearings 20 Move the differential to the left and right with pry bars and ensure small amount of end play Figure 45 Figure 45 33 ...

Page 34: ...ure 46 T Bar Wrench 22 Tighten both adjusting ring one notch to preload the diff bearings Figure 46 Adjusting Ring opposite Ring Gear 23 Adjust dial indicator to zero Rotate the ring gear to check the run out Figure 47 Run out should be within 0 008 0 20mm Rotate Ring Gear Dial indicator Pointer Figure 47 34 ...

Page 35: ... 48 Adjust the backlash by loosening the one of the adjusting ring and tightening the other adjusting ring to the equal amount Figure 48 BACKLASH SPECIFICATION BACKLASH RANGE 0 008 0 018 0 20 46 mm BACKLASH FOR NEW GEAR SET 0 012 0 30 mm WHILE REUSING OLD GEAR SET ADJUST THE BACKLASH NOTED DURING DISASSEMBLY 35 ...

Page 36: ...djusting Ring this side 26 To decrease backlash move the ring gear towards the drive pinion Figure 50 Figure 50 Loosen Adjusting Ring this side Decrease Backlash Tighten Adjusting Ring this side 27 Apply marking compound to six teeth of ring gear Rotate the ring gear forward and backward so that these teeth go past pinion to obtain clear pattern Figure 51 Figure 51 36 ...

Page 37: ...of the gear teeth and in centre between top and bottom of teeth Figure 52 Figure 52 High pattern this indicates that the drive pinion is not installed deep enough into the carrier Figure 53 Figure 53 Low pattern this indicates that the drive pinion is installed too deep in the carrier Figure 54 Figure 54 37 ...

Page 38: ... this will move the pinion away from ring gear Figure 56 30 Location of patterns to move the contact patterns to the correct location in the length of teeth adjust the backlash within specified range as follows Decrease shim pack Increase shim pack Figure 55 Figure 56 To shift the pattern towards toe of the teeth decrease the backlash Figure 57 Figure 57 To shift the pattern towards heel increase ...

Page 39: ...e value of 160 190 ft lbs Cotter Key Lock Plate 32 Install the cotter pin in the adj ring using a drift and hammer Figure 59 Install the lock plate and tighten the cap screws Threaded Holes in Cap when Lock Plate is used Shown with cotter key installed Figure 59 39 ...

Page 40: ...e torque of 75 90 ft lbs 1 8 3 2mm DIA Silicon Gasket Figure 60 34 Install the gaskets and axle shafts Figure 61 Install the washers and cap screws and tighten to the correct torque value Cap screw or Stud Nut Axle Shaft Gasket Hub Figure 61 36 Connect the propeller shaft to the input flange 37 Install drain plug and fill up with lubricant to the required level 40 ...

Page 41: ...D UNITS FIRST LUBRICANT CHANGE SUBSEQUENT CHANGES AT 1600 4800 KMS ONCE IN 80000 KMS REFER THE FOLLOWING CHART 2 FOR STANDARD INFORMATION ON LUBRICANTS CHART 2 LUBRICANT SPECIFICATION AND TEMPERATURE DESCRIPTION SAE SPECIFICATION MIN OUTSIDE TEMPERATURE 12 C 26 C 12 C 04 C HYPOID GEAR OIL HYPOID GEAR OIL HYPOID GEAR OIL HYPOID GEAR OIL GL 5 SAE 85W 140 GL 5 SAE 80W 140 GL 5 SAE 90 GL S SAE 140 41 ...

Page 42: ...ication THERE IS NO UPPER LIMIT ON OUTSIDE TEMPERATURE MAX ALLOWABLE AXLE SUMP TEMPERATURE IS 121 C USE OF SAE 140 LUBRICANT WILL GIVE LONGER HYPOID GEAR LIFE RECOMMENDED LUBRICANTS 1 GULF GEAR DB DURA MAX 85W140 42 ...

Page 43: ... 7 8 9 10 11 QTY 1 1 2 1 1 12 8 4 4 1 4 Section 7 Exploded View PART NAME Housing Assy Carrier Assy Axle shaft Finish Filler plug Drain Plug Washer Hardened Bolt drive head to housing Stud drive head to housing Nut Name plate Magnet 43 ...

Page 44: ...Section 7 Exploded View 44 ...

Page 45: ...Section 7 Exploded View 45 ...

Page 46: ...Section 7 Exploded View 46 ...

Page 47: ...Section 7 Exploded View 47 ...

Page 48: ...Spring Brake shoe return Cam shaft Washer CAM head Seal Cam shaft Bushing CAM Pin return spring Retainer Roller Roller Brake shoe Brake lining Rivets ILL No 15 16 17 18 19 20 21 22 23 24 25 26 27 Spider Brake Fitting Grease Spider Dust shield Top bottom Description Plug Dust shield Cap screw Dust shield Washer Dust shield Bracket Finish Fitting Grease Bracket Spacer Washer Washer Washer Lock Ring ...

Page 49: ...49 ...

Page 50: ...w M12 X 1 75 Grade 12 9 Standard Hex Head 105 125 143 169 Differential Case Bolt Nut M12 X 1 75 95 115 128 155 Gear To Case Cap screw M12 X 1 25 92 103 124 140 Bearing Cap Screw M16 X 2 181 221 245 300 Housing to carrier Stud Nut M12 X 1 75 75 90 101 122 Carrier to Housing Cap screw M12 X 1 75 75 90 101 122 Pinion cage cap screw M12 X 1 75 70 110 94 150 Carrier Oil Fill plug 0 75 X 14 25Minimum 34...

Page 51: ...Section 9 Adjustment and Specification 51 ...

Page 52: ...Section 9 Adjustment and Specification 52 ...

Page 53: ......

Page 54: ...he dust shields by removing the mounting bolts 13 Remove camshaft bracket mounting bolts and remove the bracket Removetheplummerblock mounting bolts and remove the plummer block 10 Remove the lock ring washers and slack adjuster from cam shaft Remove lock ring washers slack adjuster and spacer 14 Remove the mounting bolts nuts and take out the spider 54 ...

Page 55: ...heck and replace camshaft brackets if found with cracks and broken welds Check and replace plummer blocks if found cracked or damaged Figure 74c 5 Check the rollers for flat spotting and brinelling If found replace the rollers 6 Check and replace the camhead washer if found worn and distorted 7 Replace return spring anchor springs and roller retainers if found elongated and damaged It is recommend...

Page 56: ... Figure 77 2 Install the camshaft bracket in the spider with the new gasket Tighten the bracket mounting bolts To the torque of 90 120 ft lbs For front For rear 135 170 ft lbs 3 Install the camshaft along with the cam head washer 4 Check the radial play of Camshaft bushing Figure 76 the 5 While replacing seals in both spider and bracket ensure seal lips face the slack adjuster Figure 78 56 ...

Page 57: ...nstall the anchor pins Check the radial play in the bushes Figure 79 Figure 79 9 Check the gap between the shoe and linings along the sides and the ends This should not exceed 0 25 mm but between webs 0 60 mm gap is acceptable Figure 81 Figure 81 Lining to Shoe Gap Both Ends must not Exceed 010 inch 25mm Lining to Shoe Gap Both Sides must not Exceed 010 inch 25mm If the radial play exceeds 0 80 mm...

Page 58: ...etainers Squeeze the ears of the Retainers so that the Retainers fit between the shoe webs Figure 84 Figure 84 Figure 82 13 Push the retainer into the shoes until its ears Lock in the holes of the webs Figure 85 Figure 85 11 Swing and bring the bottom shoe closer to cam head Install the shoe return spring Figure 83 Figure 83 12 Install new roller retainers on the rollers 14 Install the spacer wash...

Page 59: ...e the slack adjuster re position on the splines 19 Install the dust shields Tighten the mounting bolts to the torque of 25 35 ft lbs CHECK END PLAY Recommended play is 0 8 mm maximum To reduce the play increase The spacer washer Readjust the end play when It exceeds 1 5 mm during the operation 17 Connect the slack adjuster to the air chamber pushrod 18 Check the position of the chamber push rod an...

Page 60: ...ber mounting face and the centre of the slack adjuster clevis pin Figure 88 B Figure 89 A 72 0 0 4 mm 6 The difference between the above two readings is the stroke of the air chamber this should not exceed the prescribed limit Figure 90 Figure 88 If the reading is not 72 0 0 4 mm Disconnect the yoke from slack adjuster slacken the lock nut Rotate the yoke as necessary and refit 5 While the brakes ...

Page 61: ...ng thickness Major inspection During every Re lining Brakes spider for distortion and loose mounting bolts Anchor pins and rollers for wear Camshaft and bushings for wear Return spring and shoe retaining spring for elongation Camshaft seals for leak and damage Drums for cracks scratches and scoring Ensure same type air chamber and slack adjuster are used on both sides of the axle Equal stroke leng...

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