Eixo Dif Simples Vel ENG

MAINTENANCE MANUAL
Axle Single-Reduction Differential

MS - 145/147
MS - 155
MS - 160
MS - 165
MS - 168
MS - 185
MS - 186
RS - 120
U - 180
U - 185
Edition September/11
Index
1 - Alterations to the Shaft......................................................................................... 03
2 - Introduction........................................................................................................... 04
3 - Exploded View...................................................................................................... 05
4 - Identification......................................................................................................... 07
5 - Disassembly......................................................................................................... 08
6 - Preparation for the Assembly............................................................................... 14
7 - Liquid Lock........................................................................................................... 18
8 - Chemical Joint...................................................................................................... 20
9 - Assembly.............................................................................................................. 21
10 - Adjustments.......................................................................................................... 39
11 - Main Satellite Box Blocking System..................................................................... 44
12 - Lubrication............................................................................................................ 58
13 - Torque Table........................................................................................................ 59
MAINTENANCE MANUAL
Alterations to the Shaft
In order to maintain the maintenance manual Safety
updated, for each alteration made to the shaft, a It is of paramount importance to use safety
Technical Instruction will be issued with the data equipment when maintaining the shaft.
and implications arising from this alteration.
When using a hammer or executing any ope-
In the footer of each page of this manual there rating involving impact, wear safety goggles.
is an area designated to noting down the num-
When handling parts which are hot or have
ber of each Technical Instruction which invol-
sharp edges, wear suitable gloves.
ves possible alterations occurring on that page
as shown in the example below.
MAINTENANCE MANUAL 3
Introduction
The Meritor differentials of simple speed are dri- Satellites and Planetary gears with straight
ve units which the following features: conic teeth obtained by precision forging.
Hypoid Crown and Pinion teeth cut by the Notch of the Pinion with fine teeth of an evol-
GENEROID process which leads to greater ving profile, rolled cold for greater resistan-
capacity of torque and durability than conven- ce and durability with a small screw angle to
tional gears due to a larger number of teeth in couple under pressure, with the Fork of the
gear (1 totally and 2 partially in gear) Universal Joint, the-reby avoiding the loose-
Hypoid Pinion assembled on conic roller be- ning of the pinion nut when the vehicle is sub-
arings, which absorb the axial and radial for- ject to a high vibration level.
ces and a cylindrical roller bearing at the top Lubrication channels positioned at stra-tegic
of the head, which absorbs the radial loads. points, to ensure efficient lubrication of the
Box-Unit of Satellites and Crown, mounted gears and bearings at lower speeds.
on conic roller bearings.
4 MAINTENANCE MANUAL
Exploded View
Exploded View Nomenclature
ITEM DESCRIPTION ITEM DESCRIPTION
01 Differential Box 31 Roller Bearing Cone (Inside Pinion)

02 Bearing Cover 32 Universal Joint Fork
03 Screw - Fastening Bearing 33 Dust Deflector
04 Washer 34 Pinion Sealer
05 Satellite Box - Flange Half 35 Pinion Nut
06 Satellite Box - Single Half 36 Screw (Fastening Pinion Box)
07 Satellite 37 Washer (Fastening Pinion Box)
08 Satellite Thrust Washer 38 Washer (Fastening Pinion Box)
09 Differential Crosspiece 39 Washer (Fastening Crow)
10 Planetary Item
11 Satellite Thrust Washer
12 Screw Fastening
13 Roller Bearing Cone (Satellite Box
- Flange Half)
14 Roller Bearing Cone (Satellite Box
- Single Half)
15 Roller Bearing Cover (Satellite
Box - Flange Half)
16 Roller Bearing Cover (Satellite
Box - Single Half)
17 Adjusting Ring
18 Locking Pin
19 Pinion
24 Elastic Ring
25 Pinion Box Adjusting Wedge
26 Pinion Box
27 Roller Bearing Cover (Inside
Pinion)
28 Roller Bearing (Outside Pinion)
29 Roller Bearing Cone (Outside
Pinion)
30 Pinion Roll Adjusting Wedge
Identification
The unit has ID plates on which the basic pro- Before starting service operations, identify the
duct specifications are written. unit to be repaired, looking at the ID plates fas-
tened to the differential box frame. This informa-
tion will allow correct identification of the spare
MODEL (Model)
parts required, allowing the execution of a qui-
CUST N (Customer Number) cker and more accurate service operation.
PART N (Product Number)
RATIO (Differential Reductions)
SERIE N (Serial Number)
DATE (Manufacturing Date)
DIFFERENTIAL ID PLATE
FRAME ID PLATE
AXLE UNIT ID PLATE
ID PLATE
Disassembly
Disassembly of Differential
Before starting service operations, identify the
unit to be repaired, looking at the ID plates fas-
tened to the frame and Differential Box.
Remove the draining belly, located on the
lower surface of the frame and drain all the
existing oil (figure 01).
Figure 03
Remove the half shafts.

Disconnect the cardan shaft.
Removal of the Differential

PLUG A - Loosen the differential setscrews and remo-
ve them.
Figure 01 B - Loosen the differential from the frame using
a suitable support and a jack. (figure 04).
Loosen the nuts, the lock washers and co-
nic washers of the tap bolts fastening the half
shafts. IMPORTANT:
If it is necessary to use eyebolts, the flange of
IMPORTANT: the differential box has threaded holes for this
purpose. The same setscrews of the differen-
In order to remove the conic washers, su-
tial can be used in this operation.
pport a brass bar (with O 38 mm) in the de-
pression existing at the center of the flan- If necessary, apply firm blows with a rubber
ge of the half shaft and hit it with a bronze or plastic hammer to release the differential
hammer (figure 02) or use and auxiliary nut, from the adhesive effect of the chemical joint.
hitting with a hammer on the hexagonal nut Never insert a wedge or chisel between the di-
(figure 03). fferential box and the frame so as not to cau-
se irreparable damage to their surfaces.
CAUTION:
1 - Do not hit directly on the half shaft.
2 - Do not insert wedges or chisels be-twe-
en the half shaft and the wheel to avoid
irreparable damage to these parts.
Figure 04
Figure 02
Disassembly
C - Install the unit in an appropriate support (fi- Removal of the Bearing Covers
gure 05) A - Remove and discard the pins, cotter pins
or lock of the adjusting rings of the satellite
box (figure 07).
Figure 05
D - Measure the value of the gearing gap of

the teeth of the crown/pinion pair. See the
section GEARING GAP ADJUSTMENT Figure 07
(figure 06).
B - Loosen the retaining washers and screws

CAUTION:
of the bearing covers and mark the original
Before executing the measure- positions of the covers.
ment, remove all the oil existing on
C - Manually remove the bearing covers (figure
the teeth of the crown and pinion
08).
with one of the solvents indicated
in the CLEANING section and follow
the instructions in the DRYING sec-
tion
Figure 06 Figure 08
Disassembly
D - Manually remove the adjusting rings (figure Disassembly of the Satellite Box
09). A - Check, before the disassembly, if the hal-
ves of the satellite boxes (single and with a
flange), have a marked assembly position.
If not, mark them so that the original posi-
tion is maintained in the reassembly (figure
11).
B - Loosen the setscrews of the two halves of
the box.
Figure 09
E - Remove the satellite box with safety and

place it on a bench (figure 10).
Figure 11
C - Separate the two halves of the box and re-

move the internal components, in the se-
quence indicated (figures 12, 13, 14 and 15).
Figure 10
Figure 12
Figure 13
Disassembly
E - Only if necessary, remove the crown using
an appropriate extractor or a press. Sup-
-port the crown between metal or wooden
blocks and press the half box through the
crown (figure 17).
Figure 14
Figure 17
F - If it is necessary to replace the crown and it

is attached by rivets, use the following pro-
Figure 15 cedure (L-147):
D - If necessary, loosen and remove the retai-

ning washers, nuts and bolts of the crown
(figure 16).
Figure 22
Figure 16
Disassembly
G- Remove the hypoid crown, using an appro- B - Remove the universal joint fork using an ex-
priate extractor or a press (figure 22). tractor (figure 26).
IMPORTANT:
Do not remove the fork with hammer blows,
as this may warp it, besides making deep
marks on the roller bearings, preventing
their possible reuse.
Figure 23
Figure 26
C - Remove and discard the pinion sealer (figu-

re 27).
IMPORTANT:.
In order to remove the sealer easily and sa-
fely, insert a screwdriver between the sealer
Figure 24 flange and the pinion box and make a lever
movement at several points so that it comes
Disassembly of the Pinion Box and the out gradually, without damaging the pinion
Pinion Rod box.
A - Immobilize the universal joint fork with an
appropriate tool and loosen the pinion nut
(figure 25).
Figure 27
D - Loosen the setscrews of the pinion box and

remove them together with the washers.
Figure 25
Inspeo
E - Remove the pinion box (figure 28). F - Remove and fasten the adjusting wedges of
the pinion box, so that their original position
is main-tained in the reassembly, if reusing
these components.
G - Remove the pinion using an appropri-ate
extractor or a press. Support the flange of
the pinion box on wooden or metal blocks
and press the pinion through the box (figu-
re 30).
CAUTION:
Upon using the press, wear safety
goggles.
Figure 28
Note: IMPORTANT:
Hit the pinion box a few times with a rubber Do not remove the pinion with hammer blo-
or leather hammer to loosen it. The pinion ws, as the effect of the blows may damage
box has threaded holes for using eyebolts. the roller bearings, preventing possible reu-
The same setscrews of the pinion box can se of them.
be used in this operation (figure 29).
H - Manually remove the front roller bearing
cone.
Figure 30
Figure 29
I - Remove, if necessary, the front and back rol-
CAUTION: ler bearing covers, using an appropriate ex-
Do not insert wedges of chisels be- tractor or a press (figure 31).
tween the pinion box and the diffe-
rential box to avoid irreparable
damage to these parts, as well as
to the adjusting wedges. If the ad-
justing wedges are in good condi-
tion, measure them and keep them
for the reassembly.
Even if the wedges are damaged, me-
asure the thickness of the packet
and record the dimension, as it will
be used as a reference in reassem-
bling the pinion box.
Figure 31
Preparation for assembly
J - Remove from the pinion rod manually the Cleaning
adjusting wedges of the roller bearings. (fi- The unit can undergo external washing, in or-
gure 32). der to facilitate its removal and disassembly. In
this case, all the openings should be covered
to avoid the possibility of water or humidity en-
tering the unit.
IMPORTANT :
We do not recommend washing the unit with
water after it has been disassembled. When
this cleaning system is used, the water is re-
tained in the parts. This can cause oxidation
(rust) in critical parts and allow the circula-
tion of these rust particles in the oil. This
practice can lead to premature wear of the
roller bearings, gears and other parts. Thu-
Figure 32 ds, the unit should be totally disas-sembled
as it cannot be cleaned suitably in another
K - Remove, if necessary the back roller bea- manner.
ring cone using an appropriate extractor or
a press (figure 33).
L - Remove and discard, if necessary, the elas- NEVER USE GASOLINE
tic ring, using appropriate pliers.
Wash all the components which have ma-chi-
ned or rectified surfaces (gears, roller bearin-
gs, wedges, crosspiece) using appropriate sol-
vents with a petroleum base, such as: diesel oil
of kerosene.
Wash the cast parts (satellite box, bearing co-
vers and inside of the differential box) using the
afore mentioned solvents. CAUTIONly remove
all the joint particles. See the LIQUIDJOINT
section.
Clean the breathing plugs CAUTIONly (an air
jet can be used). If it is blocked or damaged,
replace it.
Figure 33
M - Remove, if necessary, the pilot roller bea- CAUTION:

ring, using an appropriate press (figure 34).. Blocked plugs cause an increase in
internal pressure in the unit, being
able to lead to oil leaking by the
sealers.
Figure 34
Drying B - Wear (with visible lowering ) on the race of
T he parts should be completely dry, imme- dia- the cover or cone and/or deep indentations
tely after the cleaning, which must be perfor- (figure 35).
med using soft, clean cotton cloths. C - Cracks or breakages in the seats of the co-
ver and/or cone, or in the surface of the
conic rolls.
Note :
Compressed air can also be used for drying
the parts, except for the roller bearings.
CAUTION:
The recess chambers must be very
clean and dry to avoid later con-
tamination.
Figure 35
Inspection
D - Signs of friction in the conic roll cage (figure
It is of paramount importance to inspect all the 36).
unit components fully and CAUTIONly, before
they are reassembled. This inspection will re-
veal the parts with excessive wear or cracks,
which should be replaced.
Inspection of the Roller Bearings

Inspect the roller bearings of cylindrical rollers
and/or conic rollers (covers and cones) inclu-
ding those which were not removed from the Figure 36
seats upon which they were mounted, and re-
place them if they have any of the following de-
fects: E - Corrosion ( caused by chemical action ) or
cavity in the functioning surfaces (figure
A - Excessive wear on the wide surface of the 37).
conic rolls, with almost total elimination of the
central lowering, and/or a worn radius, with a
sharp edge, on the wide surface of the rolls:
(figure 34).
Figure 37
6 - Splintering or scaling in the surface of the

cover and/or cone (figure 38).
Figure 34
Figure 38
Inspection of the Crown and Pinion Pair A - Internal surfaces on both the halves of the
Inspect these gears, noting if there is any wear satel-lite box;
or damage, as cracks, depressions, splits or B - Support surface of the thrust washers of sa-
splinters. Also check the seats of the roller bea- tellites and planetary gears;
ring cones and the notch of the pinion. C - Crosspiece legs;
D - Planetary gear teeth and notches;
Note : E - Satellite teeth and holes.
The CROWN and PINION are machined ge-
ars coupled in pairs, to ensure the ideal IMPORTANT:
contact position between their teeth. So, if it
is necessary to Exchange a damaged crown If it is necessary to replace a damaged sa-
or pinion, both the gears of the pair should tellite or planetary gear, Exchange all the
be replaced. gears, including the thrust washers. The
combination of new and old parts can lead
to premature failure of the unit.
Note :
O ar comprimido pode ser empregado tam-
bm na secagem das peas, exceto para os
rolamentos.
Inspection of the Unit Satellite Box

Inspect the components of the differential
system and replace the parts which have de-
pressions, cracks, excessive ovalization in Inspection of the Half Shaft
holes and semi-holes or excessive wear tin Check if there are cracks and excessive wear
the work surfaces. Also check the work are- in the notches or teeth and also if there is ova-
as specified below (figure 39). lization in the flange holes.
Inspection of the Differential Box

Observe if there are fractures in any surface
or burrs in the machined regions.
Inspection of the Universal Joint Fork

SATELLITE BOX
Replace the universal joint fork, if it has ex-
INSIDE
cessive wear in the working area of the sealer
lips.
SATELLITES
AND WASHERS
Inspection of the Frame
Check if there are signs of cracks, loose tap
bolts, burrs or notches in the machined sur-
faces.
PLANETARY GEAR
WASHER
INSPECT
CROSSPIECE
NOTCH
Figure 39
Stocking Recovery Through Welding
The parts, after washing, drying and inspec- For the sake of safety and prevention of the
-tion, should be immediately reassembled or life of the maintenance to be executed, ME-
covered with a fine layer of the oil specified in RITOR recommends that repairs are not per-
the LUBRICATION section, in order to avoid formed through welding, which can affect the
oxidation. structural integrity of the components, as well
The parts which had top be stocked should be as cause distortions in those already submit-
covered with a good layer of oil or any other ted to the processes of thermal treatment.
substance preventing corrosion and kept in a Repairing with welding can only be approved
closed box or the equivalent, protecting them where rigorous controls are imposed with
from dust, humidity and rust (except for the equipment which, usually, is only to be found
components already protected with paint or in the manufacturing sites.
zincing, etc).
IMPORTANT :
Upon deciding if a part should be repai-
Maintenance - Recovery
red or destroyed, bear in mind that we, the
Replace all the parts which are worn or da- manufacturers, never hesitate to destroy a
maged, always using original components of part which is in any way doubtful.
MERITOR, to ensure a maintenance service
with satisfactory results, as using parts which
are not original will reduce the useful life of
the unit.
For better guidance, we indicate some basic
check criteria, for purposes of repairs and/or
replacement of the components:
A - Replace the nuts and bolts with rounded ed-

ges of the head and/or a damaged thread.
B - Replace the lock washers, plain wash-ers,
elastic rings, elastic pins and cotter pins.
C - Whenever the unit is reconditioned, also re-
place the pinion sealer.
D - Remove all the joint particles. See the CHE-
MICAL JOINT section.
E - Remove notches, stains, burrs or other im-
perfections of the machined surfaces.
F - The threads must be clean and unda-ma-
ged to obtain an exact adjustment and the
correct tightening torque.
G - Whenever possible, use a press to reas-
semble the parts.
H - Tighten all the fastening or locking com-po-
nents with the values specified in the TOR-
QUE TABLE section.
I - Remove the notches or burrs from the diffe-
rential box or frame.
Liquid lock
MERITOR adopted a liquid lock as its main The liquid locks are cured in the absence
locking element and, therefore, this section of air and as they are liquid quickly and uni-
describes the care required for the suitable formly fill all the space existing between the
use of this liquid adhesive. threads, allowing a safer and more efficient
locking to be obtained than the existing con-
ventional systems.
FEATURES OF THE LIQUID LOCKS
PRODUCT TYPE COLOR CURE TIME TORQUE

271 RED 2 HOURS
LOCTITE 241/1243 BLUE 6 HOURS
221 VIOLET 6 HOURS
THREE 1334 RED 6 HOURS MEDIUM

BOND 1305 GREEN 6 HOURS HIGH
Disassembly Cleaning
Execute the disassembly of the units locked CAUTIONly clean the threaded hole and the
originally with a liquid lock, using the normal fastening thread (screw, nut or tap bolt), totally
procedures of mechanical disassembly. eliminating the dirt, oil, grease or humidity. The
removal should be executed with a cleaning
agent, as trichloroethylene or another chlorine
CAUTION:
solvent.
Do not use impact wrenches or hammer
blows, to avoid damaging the head of the-
se components. Reassembly
If the removal of a nut, for example, beco- Before starting this operation, check the appli-
mes difficult due to the wear of its head cation places specified in the REASSEMBLY
or because it requires a rather high for- section. If there are, in this unit, for example,
ce to loosen it, reduce the resistance of screws which were not removed during the di-
the liquid lock heating the head of this sassembly of the unit, but had previous appli-
component at 150 C, approximately, at cation of a liquid lock, it is necessary to check
the same time as trying to loosen it. This the tightening condition of each one of them. In
procedure must be done slowly, to avoid this case apply the tightening torque (minimum)
thermal tension in the components of this recommended by MERITOR. If the screw does
unit. not turn, its condition is satisfactory. If it turns,
remove it and execute the procedures descri-
bed in this section.
Liquid lock
Procedure For Application
A - Apply the liquid lock so as to fill all the gap
between the threads. In the case of inter-
nal threads (with a blind hole), apply 4 to 6
drops in the fillets of the threaded hole (fig-
-ure 41).
Note :
When the hole is not passing, apply a liquid
lock in the thread of the hole, as when the
lock is applied to the thread of the screw
and it is inserted, the air existing in the hole
makes a contrary pressure, expelling the li-
quid of the lock. Figure 41
B - Tighten the fastening components with the

values specified in the TIGHTENING TOR-
QUES section.
Chemical joint
Description Procedure For Application
The CHEMICAL JOINT is a material with pasty A - Apply a continuous fillet of approximately 3
consistency, which is cured at ambient tempe- mm in diameter when the joint is NEUTRAL
rature, forming a resistant joint. SILICONE or apply with a brush when it is
The joints used by MERITOR are: FAG-3 , all over one of the coupling surfa-
ces and all the fastening holes, to en-sure a
174 and 574 (LOCTITE) and NEUTRAL SI-LI-
total Seal which avoids leakage;
CONE (DOW CORNING 780, LOCTITE 5699,
TREE BOND 1216, RHODIA 567 or 666).
FILLET APPROX.
3 mm IN DIAMETER
Cleaning
CAUTIONly clean both the junction surfaces,
eliminating the residue of the previous joint,
dirt, oil, grease or humidity. This residue should
be removed using a spatula or sandpaper,
followed by cleaning with a solvent free of oil as
xylol, or toluene or methylethylketone.
Avoid causing grooves in these surfaces, as
they can lead to later leakage.
Drying
Before application, ensure that the junction sur-
faces are perfectly dry. Figure 42
CAUTION:
Excessive application causes the
joint mass to migrate inside the
unit, and also leads to difficulties
in future disassembly. Failures in
applying the joint Cord may cause
future leakage.
B - After the application, join the two surfaces

immediately, so that the joint cord spreads
in a uniform manner;
C - Then, tighten the fastening components
with the values specified in the TIGHTE-
NING TORQUES section.
Assembly
Assembly of Pinion Box Note:
A - Install the roller bearing covers ( back and The same procedure is used to Install both
front ) in the pinion box in a press, with the the covers.
box supported on wooden or metal blocks
or use a suitable tool (figures 42 and 43). B
- Assemble the back roller bearing cone,
using a suitable tool or a press. Ensure that
the cone is perfectly aligned in the pinion
(figure 44).
COUPLING
ROLLER
BEARING
COVER
Figure 42
Figure 44
C - Assemble the pilot roller bearing, using a

suitable tool or a press (figure 45). .
Figure 42
CAUTION: Figure 45
- Check that the cover seats are clean and
free of burrs.
CAUTION:
- Check during the assembly that no wren-
ching of the pinion box material is occur- Ensure that the roller bearing is perfectly
ring. supported in the pinion. In the assembly use
an appropriate coupling which only rests in
- Ensure that the covers are perfectly sup-
the internal race of the roller bearing.
ported in their seats.
Assembly
D - Install the new elastic Ting using appropria- Roller Bearings of the Pinion
te pliers (figure 46). The control of the pre-load avoids that the roller
bearings operate with excessive pres-sure (it
reduces their useful life) or with a gap (it gene-
rates a noise and reduces the useful life of the
differential).
The pre-load is obtained by installing 1 (one)
selective wedge between the cones of the roller
bearings of the pinion (see figure 48);
ADJUSTING WED-
Figure 46
GES OF THE ROL-
LER BEARING
E - Lubricate the roller bearing covers and co-
nes with the oil recommended in the LU-
BRICATION section.
F - Install, in the pinion rod, the roller bearing
spacers.
Note :
The spacers control the adjustment of the Figure 48
preload of the pinion roller bearings.
Identification of the Adjusting Wedge
G - Position the pinion in the box. of the Pinion Roller Bearings
H - Press the front roller bearing and check the A series wedges is available for this adjustment
pre-load (figure 47). which are differentiated by the thickness, as in-
dicated in tables A, B, C and D.
The differential uses a wedge which will ensure
a pressure between the roller bearings, which
is equivalent to the following resisting torques:
USED ROLLER
NEW ROLLER BEARINGS BEARINGS
MODEL
N.m lbf.pol N.m lbf.pol
120 2,2 - 3,3 20 - 30 1,3 - 2,0 12 - 18
145/147 0,5 - 5,0 5 - 45 1,1 - 3,4 10 - 30
155 1,7 - 4,0 15- 35 1,1 - 2,3 10- 20
160 0,5 - 5,0 5 - 45 1,1 - 3,4 10 - 30

Figure 47
185 0,5 - 5,0 5 - 45 1,1 - 3,4 10 - 30
Note : CAUTION:
DO NOT INSTALL the pinion sealer before These values should be obtained without
adjusting the pre-load of the pinion roller the sealer being assembled in the pinion
bearings. box.
Assembly
MODEL RS 120 MODEL 145/147

PART N THICKNESS PART N THICKNESS PART N THICKNESS PART N THICKNESS
028079 12,12 028089 12,37 028820 17,77 028826 17,92
028080 12,14 028090 12,40 028821 17,79 028827 17,95
028081 12,17 028091 12,42 028822 17,82 028828 17,97
028082 12,19 028092 12,45 028823 17,84 028829 18,00
028083 12,22 028093 12,47 028824 17,87 028830 18,02
028084 12,24 028094 12,50 028825 17,89 028831 18,05
028085 12,27 028095 12,52
Table B
028086 12,30 028096 12,55
028087 12,32 028097 12,57
028088 12,34 028098 12,60
Table A
MODEL 155 MODEL 160 / 185

PART N THICKNESS PART N THICKNESS PART N THICKNESS PART N THICKNESS
029050 18,72 029057 18,90 029684 13,03 029693 13,18
029051 18,74 029058 18,92 029685 13,05 029694 13,20
029052 18,77 029059 18,95 029686 13,06 029695 13,23
029053 18,79 029060 18,98 029687 13,08 029696 13,25
029054 18,82 029061 19,00 029688 13,10 029697 13,28
029055 18,85 029062 19,03 029689 13,11 029698 13,31
029056 18,87 029690 13,13 029699 13,33
029691 13,15 029700 13,35
Table C
029692 13,16 029701 13,38
Table D
RECOMMENDED RANGE IMPORTANT:

MODEL
MM INCHES The parts are identified through the recor-
ding of the thickness on one of the surfaces.
120 17,48 - 17,53 0,688 - 0,690
145/147 17,87 - 17,97 0,704 - 0,708 We recommend that the start assembly is per-
formed with the wedges situated in the range
155 18,79 - 18,92 0,740 - 0,745 recommended in table E, which will allow the
adjustment desired to be obtained immediately
160 13,18 - 13,28 0,519 - 0,523 (in most cases):
185 13,18 - 13,28 0,519 - 0,523
Table E
Assembly
Pinion Roller Bearing Pre-Load Adjust- D - Pull the dynamometer horizontally and ob-
ment serve the value (pounds or kilos) recorded
The pre-load value of the pinion measured as on its scale.
per fig. 49 is the one indicated in the table be-
low: Note :
USED ROLLER Note the value recorded with the box rota-
NEW ROLLER BEARINGS
MODELO
BEARINGS ting and not the start value. The start value
KG LB KG LB gives a false reading.
120 3,4 - 5,1 7,7 - 11,8 2,0 - 3,1 4,6 - 6,9
145/147 0,7 - 6,7 1,7 - 15,0 1,5 - 4,6 3,3 - 10,0 Method Without Using Press
155 2,1 - 4,8 4,5 - 10,6 1,3 - 2,8 3,0 - 6,0 If a press is not available during the service
160 operation, use the following procedure:
0,5 - 5,1 1,3 - 11,4 1,1 - 3,5 2,5 - 7,6
185 0,5 - 5,1 1,3 - 11,4 1,1 - 3,5 2,5 - 7,6
A - Lubricate all the hypoid pinion roller bea-
rings with the oil specified in the LUBRICA-
Method Using Press TION section;
Note :
B - Install the fork/flange of the universal joint
If a press is not available, use the assembly (without the pinion sealer);
method with the yoke (universal joint fork).
C - Immobilize the pinion (through the fork/flan-
A - Lubricate all the pinion roller bearings with ge of the universal joint) using a suitable de-
the oil specified in the LUBRICATION sec- vice;
tion. D - Tighten the pinion nut with the minimum
B - Press the cone of the front roller bearing value specified in the TIGHTENING TOR-
and rotate the pinion box several times to QUES section;
ensure a suitable seating between covers E - Turn the pinion box several times to en-su-
and cones. Maintain the pinion box under re a suitable seating between covers and
the press with an applied load. cones;
F - Wind a cord around the pilot diameter of the
MODEL LOAD (TON) pinion box with a dynamometer (balance of
good quality), tied at its end. (figure 49);
120 6 (MAX)
G - Pull the dynamometer horizontally and ob-
145/147 11 serve the value (pounds or kilos) recorded
155/160/185 14 on its scale;
C - Wind a cord around the pilot diameter Note :

of the pinion box with a dynamometer
(balance of good quality), tied at its Note the value recorded with the box rota-
end (figure 49). ting and not the start value. The start value
gives a false reading.
H - If after tightening with the maximum limit of

torque, the desired pre-load is not obtained,
replace the wedges by thinner ones and re-
-peat the checking procedure;
I - Remove the fork/flange of the universal joint
and continue to reassemble the differential.
Figure 49
Assembly
Pinion Assembly Depth Adjustment
- Without the aid of a Special Tool
The depth adjustment of the pinion aims to po- WEDGES
sition the pinion related to the crown to obtain
an ideal contact between the teeth of these ge-
ars (figures 50 and 51);
eXAMPLE
ms 124
Figure 52
- With the aid of Special Tool 140 / 145

CAUTION:
dn: 173,0
In the operations described below, check
the cleanness, mainly:
1 - Of the contact surfaces between the
components of the special tool;
Figure 50 Figure 51 2 - Of the contact surfaces of the compo-
nents of the special tool with the two
INCREASE THE REDUCES THE
boxes of the differential and the pinion,
DEPTH DEPTH which is fundamental.
A series of wedges is available to adjust the Adjust the depth of the pinion with the aid of the
depth of the pinion, which are differentiated by following components of the tools (figure 53):
the thickness. (figure 52) 1. Centralized shaft
2. Pinion simulator
3. Adapter
MODEL PART N THICKNESS (mm)
4. Circlet
029101 0,20
5. Knurled nut
029345 0,10
120 6. Clock support
029099 0,05
029311 0,05 7. Wedge
028807 0,08
8. Centralizing disk
028808 0,12
145/147 9. Centralizing disk
028809 0,20
028810 0,50
029522 0,06
029523 0,12
145 (NOVO)
029524 0,25
029525 0,50
028453 0,08
155 028454 0,12
028455 0,25
029390 0,05
029391 0,12
160/185
029386 0,20
029387 0,50
220328814 0,05
22038815a 0,12
185 0,20
2203B8816
2203C8817 0,50
Figure 53
Assembly
Install in the pinion simulator the pinion back Install on the other surface of the pinion box the
roller bearing adapter (figure 54). front roller bearing (figure 57).
1. Adapter
2. Pinion simulator
Figure 54 Figure 57
Install in the adapter back roller bearing of the Place the circlet of the pinion front roller bea-
pinion (figure 55). ring and the knurled nut, tightening the latter
1. Adapter manually (figure 58).
1. Circlet
2. Knurled nut
Figure 55
Install the pinion box with the surface which will

fit in the differential box turned downwards on
the pinion back roller bearing (figure 56).
Figure 58
Figure 56
Assembly
Check that the contact surfaces of the pinion Turn the differential box 180 degrees.
box and the differential box are clean and free of Check that the housing bearings of the satelli-
scratches or protuberances. te roller bearings and centralizing disks of the
Install the pinion box without the height adjust- tools are perfectly clean, lubricating them af-
ment wedges in the differential box (figure 59). terwards with a slight oil film.
Install the wedge on top of the pinion simulator
(figure 61).
1. Wedge
2. Pinion simulator
3. Bearings
Figure 59
Place four bolts and apply a start tightening in a

crosswise sequence.
Then, with a torquemeter and in the same se-
quence, apply the final tightening, as per the
torque specified in the table page 46) (figure Figure 61
60).
Install the centralizing disks with their respecti-
ve shaft in the housing bearings of the satellite
box roller bearings (figure 62).
3. Centralizing shaft
Figure 60
Figure 62
Assembly
Install in the support a centesimal comparator. This value is called the nominal gauge of the
Place the support and the feeler gauge of the differential in question.
comparator on the wedge at the point of the pi- The nominal gauge is the distance existing be-
nion simulator - standard surface adjusting the tween the touching surface of the pinion back
instrument dial to reading 0 (zero) (figure 63). roller bearing and the crown center. (figure 64).
1. Wedge
2. Clock support
3. Comparator
4. Pinion simulator
(CN) Nomi-
nal GAUGE
Figure 64
MODEL (CN) NOMINAL GAUGE
Figure 63 120 193,68

145/147 195,28
Then, with the support of the comparator firmly
supported on the wedge, on the point of the pi- 155 219,08
nion simulator, place the feeler gauge on the
160 235,00
centralizing shaft.
Next, move the feeler gauge transversally to 185 254,00
the centralizing shaft, until the instrument poin-
ter indicates a maximum value. This value whi- Check and Note the number recorded at the
ch indicates that the feeler gauge is exactly on top of the pinion. This value indicates, in accor-
the diameter of the centralizing shaft. dance with the signal which precedes it, how
many hundredths of millimeters must be added
Note the maximum value (Vm) indicated by the
to or subtracted from the maximum value (Vm)
pointer of the comparator (figure 64).
obtained in the reading of the comparator clock
(figure 65).
Figure 65
Figure 64
Assembly
We list below some cases as an example to 3. Recording (-06) at the top of the pinion
determine the quantity of wedges to be instal-
led, between the pinion box and the differential
A - Measurement obtained in the clock reading;
box:
B - Recording at the top of the pinion (-06);
1. Recording (0) zero at the top of the pinion.

0.58 mm
A - Measurement obtained in the clock reading;
0.06 mm-
B - Recording at the top of the pinion;
Total 0.52 mm
0.58 mm
In this case, install the quantity of wedges (0.52
0.00 mm+
mm) resulting from subtracting A - B (figure 68).
Total 0.58 mm
Install the same quantity of wedges ob-tained
in the reading of the clock (A) 0.58 mm (figure
66).
Figure 66
Figure 68
2. Recording (+06) at the top of the pinion
A - Measurement obtained in the clock reading; Method without Special Tool

B - Recording at the top of the pinion (+06); If there is no exchange of crown and pinion pair,
maintain the wedge pack of the pinion box.
0.58 mm
If there is an exchange of pair, check the rea-
0.06 mm+
ding in the old pinion and the new pi-nion (fi-
Total 0.64 mm gure 68). Calculate the difference and add or
In this case, install the quantity of wedges (0.64 remove wedges of the original pack.
mm), resulting from adding A + B (figure 67).
Figure 68
Figure 67
Assembly
EXAMPLE OF CALCULATION No. 1 C - Pinion variance (VP)
All the pinions have an individual variance re-
Old Pinion +06 lated to their DN, which is recorded at the top
of their head. This variance is expressed in
New Pinion -03
thousandths of an inch and preceded by a +
Difference 09 or - sign.
Action: Remove 0.09 mm from the origi-nal If there is no exchange of crown and pinion pair,
wedge pack. maintain the wedge pack of the pinion box.
If there is an exchange of pair, check the recor-
EXAMPLE OF CALCULATION No. 2 ding in the old pinion and the new pinion (figure
68). Calculate the difference and add wedges
> to or subtract them from the original pack.
Old Pinion = -06
>
New Pinion = +03
Difference 09 EXAMPLE OF CALCULATION No. 1
Old Pinion +6
Action: Add 0.09 mm to the original wedge New Pinion -3
pack. Difference 9
Note: If the original wedge pack is lost, start Action: Remove 0.009 from the original
from the nominal pack of: wedge pack.
THICKNESS
MODEL THICK. (mm)
(inches) EXAMPLE OF CALCULATION No. 2
120 0,96 .020 + .010=.038
>
145/147 0,96 .020 + .010=.038 Pinho Velho = -6
>
155 0,906 (2).010 +(2).005=.038 Pinho Novo = +3
Diferena 9
5 Adjustments of Differential Action: Add 0.009 to the original wedge

L-147 pack l.
The process for adjusting this unit is basically Note: If the original wedge pack is lost, start
the same as for models 140 and 145, except from the nominal pack of: 0.90 mm (0.035).
that the wedges must be executed in inches, as
these gears are NOT metric.
A - Identification of the Pinion Box Adjustment THICKNESS

MODEL CODE
Wedges MM INCHES
029101 0,20 0,008
120 029101 0,10 0,004
029101 0,5 0,002
029101 0,3 0,001
B - Nominal dimension of pinion assembly:
DN = 7,625
Assembly
Assembly of the Pinion Sealer Installation of the Pinion Box in the
1 - Install the pinion sealer as indicated below: Differential Box
a - If the sealer does not have the external dia- A - Install the pinion box wedges already selec-
meter rubberized, apply a sealing paste (in- ted, in the differential box with 2 guide pins
dustrial adhesive 847 3M) on the external (figure 71).
surfaces of the pinion sealer.
Note :
Place the thickest wedges at the ends of the
CAUTION: pack and the finer ones in the middle.
Ensure that the lips of the sealer
are free of dirt or particles which
may cause possible leakages.
b - Press the pinion sealer with a coupling or

install it with the device.
Ensure that the sealer flange is level with the
top of the pinion box. It is important that the
coupling diameter is larger than that of the sea-
ler (figures 69 and 70).
Figure 71
B - Install the pinion box. If necessary use a

rubber or leather hammer (figure 72 ).
Cassete Type
for Shafts 145 - 155
Tri-labial
Industrial Adhesive
Figure 69
Figure 72
Figure 70
Assembly
C - Apply sealing paste FAG-3 to the thread of IMPORTANT:
the pinion box setscrews. Do not use a hammer to install the fork of
D - Install and tighten the washers and sets- the universal joint, as it can be damaged.
crews of the pinion box, with the value spe-
cified. See the TORQUES TABLE. (figure
73 ).
6. With a torquemeter on the pinion nut, che-
ck the resisting torque value (pre-load) to
turn the pinion. Increase if necessary the
torque applied to the pinion nut (until the
maximum limit allowed), to handle the va-
lues specified. (figure 75).
USED ROLLER
NEW ROLLER BEARINGS BEARINGS
MODEL
N.m lbf.pol N.m lbf.pol
120 2,2 - 3,3 20 - 30 1,3 - 2,0 12 - 18
145/147 0,5 - 5,0 5 - 45 1,1 - 3,4 10 - 30
155 1,7 - 4,0 15- 35 1,1 - 2,3 10- 20

Figure 73
160 0,5 - 5,0 5 - 45 1,1 - 3,4 10 - 30
185 0,5 - 5,0 5 - 45 1,1 - 3,4 10 - 30

5. Immobilize the fork of the universal joint
with a suitable tool and tighten the pinion
nut with the value specified. See TORQUES
TABLE. (figure 74 ).
Figure 75
Figure 74
Assembly
Assembly of the Satellite Box D - Install the fastening components of the cro-
A - Apply the lubricating oil specified in the LU- wn and tighten the screws with the tor-que
BRICATION section in all the components specified in the TORQUES TABLE.
of the satellite box, before installing them;
B - Heat the crown in warm water, at the tem- Note:
perature of approximately 70-80C, during Apply to the screws HIGH TORQUE locking
10 minutes, to allow it to be placed manu- paste (LOCTITE 271 or THREE BOND 1305).
ally. See section LIQUID LOCK.
E - Assemble the new cones of the roller bea-

CAUTION:
rings in the two halves of the bipartite sa-
Wear appropriate gloves to hand- tellite box, using a suitable tool and a press
le the heated part. (figure 77).
IMPORTANT:
The installation of the crown with pre-hea-
ting ensures the correct seating of it in all
the common contact area with the satellite
box, as when the crown is as-sembled on
the press or turned on the satellite box, the-
re may occur a wrenching of metallic par-
ticles which are lodged between these 2
parts, causing misalignment of the crown
and making final adjustments of the diffe-
rential difficult. See the ADJUSTMENTS
section.
C - Install the crown in the flange half of the sa-

tellite box. If the crown is not seated satisfac- Figure 77
torily, repeat step 2 (figure 76).
CAUTION:
- Check that the cone seats are clean and
without burrs;
- Check, during the assembly operation
that no material wrenching is occurring in
the box;
- Ensure that the cones are perfectly sup-
ported on their respective seats.
F - Position the planetary gear with its thrust

washer in the flange half box.
G - Assemble the crosspiece, the satellites with
the respective washers (figure 78).
Figure 76
Assembly
J - Initially install four setscrews of the satelli-
te box at equally spaced points and tighten
them with the torque specified. See the
TORQUES TABLE.
K - Assemble the remaining screws and tighten
them with the torque indicated in item 10.
See the TORQUES TABLE.
Note:
Figure 78 Apply to the screws HIGH TORQUE locking
paste (LOCTITE 271 or THREE BOND 1305).
H - Then position the planetary gear opposite

its thrust washer in the box flange half (fig-
-ure 79).
Figure 79
I - Install the satellite box single half, ob-ser-

ving the original alignment (figure 80).
MARCAS
Figure 80
Assembly
Check of the Resistance to Rotation of C- Install the tool coupling it to the planetary
the Satellite / Planetary Gear Unit gear notch (figure 83).
Torque specified:
68 N.m (50 lb.ft) maximum.
Note :
A suitable tool for checking can be made
from a cut solar half shaft, with a nut welded
to its end (figure 81).
Figure 83
D - Place a torquemeter at the end of this device

and check the resistance to the rotation of
the satellite/planetary gear unit. The value
should be less than that specified (figure 84).
Figure 81
A - Place a protector in the vise (filing block) of

bronze, aluminum or plastic to protect the
crown.
B - Fasten the satellite box in the vise (figure
82).
Figure 84
E - If the value exceeds that specified, disas-

semble the satellites and planetary gears of
the satellite box.
F - Check the parts to discover the reason for
the excessive resistance. Repair the cause
or change the parts.
G - After fixing the problems, assemble the parts
and repeat the procedure from A to D.
Figure 82
Assembly
Assembly of the Satellite Box Unit in CAUTION:
the Differential Box If it is not possible to turn the rings manu-
A - Support the covers on the cones and assem- ally (without applying force) it is because
ble the unit in the differential box (figure 85). they are out of position. Remove the covers
and reposition the adjusting rings to avoid
irreparable damage to the differential box
and bearing covers.
Assembly of the Satellite Box/Adjustment

of the Gears. (figure 88)
Figure 85
B - Place the adjusting rings in the bearings tur-

ning them manually until touching the roller
bearings (figure 86).
ring side ring opposite

of coro side
Figure 88
A quick and accurate way to assemble the sa-

tellite box and adjust the gap of the gearing
(between teeth) and the pre-load of the roller
bearings, is as follows:
A - Assemble the satellite box, tightening the

ring on the crown side until eliminating the
Figure 86 gap. Then, loosen it by three or four cas-
tles (value of approximation for gap betwe-
C - Position the bearing covers tightening them
en teeth).
slightly (figure 87).
B - Tighten the ring opposite until eliminating
the gap of the roller bearings. Next, tighten it
by two to three castles (new roller bearings)
or one to two castles (used roller bearings).
Then, check the gap of the gearing (see ta-
ble page 39). If necessary, adjust it loose-
ning and tightening the ad-justments rings as
in the figure .
C - The pre-load indicated (1.7- 3.5 N.m (15-35
lbf inch)) will be obtained with this procedure.
(figure 89)
Figure 87
Assembly
D - Apply the liquid lock (Loctite 271 or Three
Bond 1305) to the thread of the bearing
setscrews.
E - Install and tighten the bearing setscrews
with the respective washers, with the value
specified. See the TORQUES TABLE.
F - Adjust the pre-load of the satellite box roller
bearings.
Specified: 1.7- 3.5 N.m
increases reduces
gap
G - Adjust the gearing gap. See the ADJUST-
gap
MENTS section.
H - Check the contact of the teeth of the crown/
pinion pair. See the ADJUSTMENTS sec-
tion.
I - Install the cotter pin and/or lock of the ad-
Figure 89
-justing rings with the torque specified. See
the TORQUES TABLE. (figure 91).
IMPORTANT:
In order to move the rings in the final adjust-
ments, always use a T type bar or ordinary
bars which engage in to opposite castles, as
illustrated in the figure. Never hit the castles
with hammers or chisels, as this may cause
irreparable damage to the adjusting rings.
(figure 90)
Figure 91
Figure 90
Assembly
Installation of the Unit Differential Box
in the Frame
A - Apply neutral silicone in the opening of the
frame. See the CHEMICAL JOINT section
(figure 92).
B - Position the differential in the frame. Use a
hydraulic Jack or a block and tackle.
Figure 92
CAUTION:
Do not try to place the differential in the fra-
me using a hammer, as the flange may be
deformed and cause a leakage.
C - Apply high torque liquid lock to the thread

of the differential box setscrews. See the
LQUID LOCK section.
D - Install the differential box setscrews with
their respective washers and alternately ti-
ghten the first four spaced at 180 and then
the others with the specified torque:
BOLT NUT
MODEL
N.m lbf p N.m lbf p
120 95-150 70-110
145/147 270-330 200-245
155 270-330 200-245
160 270-330 200-245
185 270-330
Adjustments
Gearing Gap E - If necessary increase or reduce the gearing
A - Check the gearing gap of the crown/pinion gap, by loosening the adjusting ring on the
pair, using the following procedure: right side and in the same proportion tighte-
ning the left side or vice versa, as required
B - Support the pointer of a comparator clock in
(figure 94).
the tooth of the crown (figure 93).
Figure 93
Figure 94
C - Immobilize the pinion, manually move the

crown in both directions of rotation and take Note:
the reading. The gap value should be as per
It is important to maintain the propor-tion
the table below.
between tightening and loosening, i.e.: the
D - If necessary increase or reduce the gearing same amount that is loosened in one ring
gap, by loosening the adjusting ring on the must be tightened in the other so that the
right side and in the same proportion tighte- pre-load of the satellite box roller bearings
ning the left side or vice versa, as required is maintained
(figure 94).
IMPORTANT:
MODEL
GAP If reusing the crown/pinion pair, it is advisa-
milmeters ble to maintain the original gearing gap.
120 21 - 45
145/147 21 - 45
155 0,26 - 0,50
160 0,25 - 0,51

185 0,25 - 0,41
Adjustments
Contact of the Crown and Pinion Teeth C - Check if the contact obtained by the manual
Check of the Differential Contact Models 120 - process complies with the standard (figure
145 - 147 - 155 - 160 - 185 97). If not, use the correction methods indi-
cated in the item Incorrect Contacts.
Checking Process
Note:
A - Apply yellow iron oxide (diluted in fine oil) to
some of the crown teeth (figure 95). - Upon obtaining the correct contact on the
convex side (forward gear), the contact on
the concave side (reverse gear) will auto-
matically be satisfactory (figure 97).
- With the application of load in the vehicle,
this contact will practically encompass all
the length of the tooth, approaching its
toe (figure 98).
Figure 95
B - Brake the crown, with the aid of a lever or

lath simulating a load and turn the pinion
manually, until obtaining the impression of
contact on the convex side (forward gear)
of the crown teeth (figure 96).
Figure 97
Figure 96
Figure 98
Adjustments
Satisfactory Contact Incorrect Contact
To make it easier, we indicate the terminol-ogy Variances Concerning the Height of the
used in this section (figure 99). Tooth
The contact standard for the manual process If the pinion is not at the correct depth, the con-
indicates that the gears are in the correct posi- tact can have variance related to the height of
tion, resulting in a contact area between the toe the tooth. In this case, correct its position va-
and heel/top and root of the tooth. Figure 97. rying the thickness of the wedge pack under
the pinion box. (figures 101 and 102)
Figure 99
If the convex side is satisfactory, consider the

contact of the concave side of the tooth (rever-
IT REDUCES THE THICK-
se gear) automatically accepted. Figure 101 NESS OF THE WEDGE
The standard with application of load shows PACK
the contact resulting when the gears approved
by the manual process undergo a load action
(work operation). The contact area extends
to all the length of the tooth and the top of the
standard approaches the top of the crown tooth
(figure 100).
IT INCREASES THE THI-

Figure 102 CKNESS OF THE WEDGE
PACK
Figure 100
Adjustments
CONTACT
MEANING HOW TO CORRECT
OBTAINED
Level It indicates that the pinion is very far Approach the pinion reducing the thi-
Contact from the crown, resulting in a contact ckness of the adjusting wedge Pack of
very near the top of the tooth (figure the pinion box (see the Pinion Assembly
101). Distance Adjustment section). This will
make the contact move to the tooth root
(figure 101).
Bottom It indicates that the pinion is very Separate the pinion increasing the
Contact near the crown, resulting in a contact adjusting wedge pack thickness of the
very near the tooth root (figure 102). pinion (see the Pinion Assembly Distan-
ce Adjustment section). This will make
the contact move to the top of the tooth.
(figure 102).
Variances Concerning the Tooth Length

Then, check if the contact has variance related
to the tooth length. If so, alter the crown depth,
varying the gearing gap.
CONTACT
MEANING HOW TO CORRECT
OBTAINED
Toe It indicates that the crown is very Separate the crown increasing the ge-
End near the pinion, resulting in a contact aring gap (if necessary, until the maxi-
very near the toe of the tooth (figure mum allowed) so that the contact area
Contact
103). moves in the direction of the tooth heel,
approaching in the manner indicated in
figure 97 (see the Gearing Gap Adjust-
ment section).
Heel It indicates that the crown is very far Approach the crown reducing the gea-
End from the pinion, resulting in a contact ring gap (if necessary, until the minimum
very near the heel of the tooth (figure allowed) so that the contact area moves
Contact
104). in the direction of the tooth toe, appro-
aching in the manner indicated in figure
97 (see the Gearing Gap Adjustment
section).
Contacto Extremo de Figure 103 Contacto Extremo Figure 104

la Punta Taln
Adjustments
Check of the Differential Contact
Model RS120
The hypoid pinion and crown teeth of the differen-
tial RS120 are cut by the conventional process.
Check the contact of the teeth of these gears
using the same correction procedure specified
for the models 120, 145/147, 155, 160 and 185,
but considering the contact standards illustrated
in figures 103, 104, 105, 106, 107, 108.
STANDARD FOR APPLYING Figure 107

load
STANDARD FOR Figure 105

MANUAL PROCESS
BOTTOM CONTACT Figure 108
IMPORTANT:
Upon noting that the contacts are correct,
lock the adjusting rings with a pin or cotter
pin.
CAUTION:
In the assembly, a cotter pin may be used
where originally the pin was assembled, but
NEVER assemble a pin in the hole where a
cotter pin was used.
LEVEL CONTACT Figure 106
Main Satellite Box Blocking System
Warning and Danger Messages Removal of the Differential Unit of the Shaft
Read and observe all the Warning and Precau- Frame.
tion alert messages. They contain information Before the differential unit can be removed or ins-
which can help to prevent serious personal injury, talled, the locking system of the main satellite box
damage to components, or both. must be activated and maintained in the activated
or locked position. In the locked position, there
will be a sufficiently large gap between the locking
WARNING: ring and the shaft frame to allow the removal or
In order to prevent serious injury to the eyes, installation of the differential unit.
always wear safety goggles when executing
services or maintenance in the vehicle. Note:
If the half shaft is removed to tow the vehi-
Description cle and the differential is in the unlocked or
Some traction shafts of ArvinMeritor are equi- uncoupled position, install the half shaft of
pped with a Blocking System of the Main Sa- the left side in the shaft frame before conti-
tellite Box (DCDL). This locking of the satellite nuing. Execute the following steps to reins-
box is operated by an air drive mechanism and tall the half shafts in the shaft frame:
assembled in the differential unit. When activa- 1. Remove the protection, if used during the to-
ted, the drive mechanism moves a locking ring wing of the vehicle, of the wheel hubs.
sliding it on a notch in the half shaft. When cou- 2. If the traction shaft is equipped with a locking
pled, the locking ring links the half shaft to a system of the main satellite box, activate the
second notch which exists on one of the sides system to the unlocked or uncoupled posi-
of the satellite box. Both the traction wheels tion. Install the half shaft with two notches
are now simultaneously coupled, not allow-ing and new joints in their place as follows:
the differential action of the main satellite box. A. Place the half shaft and joint in the hub and
Figure 109 frame until the half shaft touches the gearing
ring.
Note : B. Lower, raise and turn the half shaft by the
The ArvinMeritor differential unit models flange until the notch of the half shaft and the
equipped with a locking system of the main gearing ring are engaged.
satellite box are made in metric dimensions. C. Push the half shaft inside the frame of the
When these differential units are maintai- shaft until the half shaft touches the planeta-
ned, it is very important to use metric size ry gear of the main satellite box.
tools suited to the fastening components. D. Lower and turn the half shaft by the flange
until the notch of the half shaft and of the
planetary gear of the differential are enga-
ged.
E. Place the half shaft completely inside the
frame until the flange and joint are adjusted
against the wheel hub.
Gearing or Locking of the DCDL CDDL FASTENED BY SCREWS
WARNING:
During the disassembly of the DCDL or the housing hole for the
manual gearing screw air line
removal of the differential unit, when the
DCDL is in the locked or engaged position
and one of the vehicle wheels is raised from manual
gearing cylinder
the ground, do not turn the motor on or cou- cover
screw
ple the transmission. The vehicle may move
and cause serious personal injury. The
components may also be damaged.
electric
Park the vehicle on a level surface. Block the cable
wheels to prevent the vehicle from moving. PLUG and
position of opera-
joint
Support the vehicle on safety supports. Do tion hole
not work under a vehicle supported only by housing hole for the
a jack. The jack can slip or break. Serious plug and joint in the Figure 111
personal injury and damage to the compo- lower joint
nents may occur.
Manual Method
Use the following manual method to couple the 2. Remove the drainage plug from the frame
mechanism of the DCDL in the locked position: and drain all the lubricant.
If an air line is not available or the differential unit 3. Use a jack to raise the wheel of the left side
is stocked for later use, use this manual gearing of the traction shaft.
method for the DCDL. Figure 110 and Figure 111. 4. Place a safety support under the spring seat
of the left side to maintain the vehicle in the
raised position.
5. Disconnect the cardan shaft of the differen-
tial unit input fork.
6. Disconnect the air line of the vehicle of the
threaded CDDL differential locking drive system between
shafts and of the main satellite box.
7. Remove the connection and the joint from
housing the central hole of the cylinder fastened by
hole a thread or of the flanged cylinder fastened
Cylinder by screws of the DCDL.
air 8. Remove the manual gearing screw from the
hose housing hole in the cover of the cylinder fas-
tened by screws or in the box of the mecha-
nism with a cylinder fastened by a thread.
Figure 110 and Figure 111.
Note:
manual gearing screw For the drive mechanism unit of the DCDL
fastened by screws, the housing hole of
the plug and joint is on the opposite side
Figure 110
of the housing hole of the manual gearing
screw. Figure 111.
9. Install the plug and the joint of the lower hou-
1. Park the vehicle on a level surface. Block the sing threaded hole in the cylinder cover or
wheels to prevent the vehicle from moving. in the box of the mechanism fastened by a
thread.
10.Install the manual gearing screw in the thre-
aded hole in the center of the cylinder or in
the threaded hole of the cylinder cover, as bosseS
built.
CAUTION
There will be a small resistance
of the spring which you will feel
when threading the manual gea-
ring screw. If you feel a high resis-
Figure 112
tance before reaching the locked
or engaged position, stop tighte-
ning the screw, or the cover, fork 3. Remove the drainage plug from the lower
and screw thread may be damaged. part of the frame and drain the lubricant.
11. Turn the manual adjustment screw to the 4. Disconnect the cardan shaft of the input fork.
right until the head is approximately 6 mm 5. Disconnect the air line of the vehicle which
(0.25) from the cylinder cover. Do not turn activates the blocking system of the differen-
the screw beyond its normal stop. tial between shafts and of the main satellite
A high resistance in the screw indicates that box.
the notch of the gearing ring and of the satellite 6. Install a connector for a suitable air line in
box are not aligned or engaged. To align the the main satellite drive mechanism unit.
notches, use the following procedure: 7. Install the air line in the connector.
A. Turn the left Wheel to align the notch of the CAUTION
gearing ring with the satellite box while you When using an auxiliary air sour-
turn the manual gearing screw. ce to engage the DCDL, the source
B. When you feel a normal slight resistance of should be maintained connected
the spring again in the gearing screw, the until the removal of the differen-
notched items will be engaged. Continue tial of the shaft frame. Do not dis-
to turn the ma-nual gearing screw until the connect the auxiliary air line or
head is approximately 6 mm (0.25) from reduce the pressure for the DCDL
the cylinder cover. The screw will now be before removing the differential
in the position for maintenance and the lo- unit from the shaft frame. The com-
cking system of the differential will be enga- ponents may be damaged.
ged. 8. The air line should supply the mechanism
12. Remove the differential from the shaft fra- with a regulated pressure of 120 psi (827
me. kPa).
13. Release the locking of the differential by 9. Check if the DCDL is engaged.
removing the manual gearing screw and 10. Remove the differential unit from the shaft
seal the cover of the cylinder fastened by a frame.
screw or the threaded cylinder.
11. Close the air source to the DCDL.
12. Disconnect the air line of the main satellite
Method with the Auxiliary Air Source box drive mechanism unit connector.
1. Park the vehicle on a level surface. Block the
wheels to prevent the vehicle from moving. Main Satellite Box and its Blocking Sys-
2. Use a jack to raise the wheel on the left side tem
of the shaft. Place a safety support under the Drive mechanism unit with a cylinder faste-
left side of the frame to maintain the vehicle ned by a Thread.
in this raised position. The current project of the locking fork does not
use elastic pins. Bosses on the internal surface
of the fork maintain the gearing ring in place.
Figure 112.
1. Check that the drive system is released and 5. Place the piston and cylinder unit in a vise
that the manual gearing screw was removed protected by bronze filing blocks. Remove
from the drive mechanism cylinder. the piston and O ring from inside the cylin-
2. Hit the gearing ring with a rubber hammer to der. Use a small bar placed through the hole
loosen it and remove it from the gearing fork. of the top of the cylinder and push the piston
Figure 113 outwards. It may be necessary to use a small
rubber hammer CAUTIONly to hit and remo-
ve the piston outwards. Figure 116.
suitable
diameter
bar
gearing ring fork gearing ring
Figure 113
3. Remove the locking mechanism sensor swi- Figure 116

tch, if used, and its locking nut from the diffe-
rential box. Figure 114. 6. CAUTIONly remove the O ring from the pis-
ton. Use the point of a small tool to facilitate
this removal. Be very CAUTION not to dama-
ge the piston. Figure 117.
Figure 114
4. Remove the locking system drive piston and

cylinder unit turning it to the left. Figure 115.
Figure 117
7. Check the O ring to identify any type of da-

mage as cuts, splits.
If the O ring is damaged, replace it by a
new ring when you reassemble the com-
ponents.
8. Clean and inspect all he drive mechanism
unit parts.
Figure 115
9. Pull the locking fork drive shaft and remove it
from the differential box. Figure 118.
gearing fork
Figure 120
box of the dcdl

cast in the diffe- This unit is disassembled in the same manner
drive
rential box as in the differentials without the satellite box
shaft locking mechanisms.
Figure 118
Drive Mechanism Unit Fastened by Screws
10. Remove the spring from the differential box
locking fork drive shaft spring. Figure 119. 1. To remove the gearing ring from the block-
-ing mechanism, withdraw the two retaining
elastic pins of the ring until they are level
MOLA DO EIXO DE
with the internal surface of the locking ring
ACIONAMENTO fork. Figure 121.
2. If necessary, remove the blocking drive me-
chanism.
drive
shaft
spring
Figure 119
ELASTIC PINS - Wi-
thdraw until they are fa-
11. If elastic pins are used, use a hammer and cing the internal surface
a bronze punch to remove the pins from the of the gearing ring fork
covers of the bearing and the adjusting ring.
If cotter pins or screws are used, remove Figure 121
them.
12. Remove the adjusting rings and setscrews
and washers from the bearing covers. Mark A. Remove the mechanism sensor switch and
one of the bearing covers and the differential its locking nut.
box so that these parts are assembled in the B. Remove the four screws and washers which
same position when reassembling the diffe- fasten the cylinder cover. Remove the co-
rential. ver. In the Series 160 differentials, remove
13. Raise and remove the satellite box unit from the copper joint. Figure 122.
the differential box. Figure 120. C. Remove the drive mechanism piston and
cylinder.
D. Remove the locking ring fork shaft. It may
be necessary to use heat to separate the
fork shaft.
Note: DCDL Mechanism Unit with Fastening by
Some models use a Silastic seal instead of Thread.
a plain washer in step E. There is also an
elastic pin installed in the drive shaft and Install the blocking drive mechanism unit of the
it is used as a stop for the spring. It is not satellite box after it has been installed and the
necessary to remove this elastic pin during gears and roller bearings have been adjusted.
a normal disassembly. The drive mechanism of the satellite box blo-
E. Remove the spring from the drive shaft and cking fastened by thread is shown in figure 123.
the plain washer.
F. Remove the drive fork and continue with THREADED VERSION UNBLOCKED
step 11 in the previous procedure.
electrical connec-
tion for sensor
drive shaft and
springs
fastening position
of manual gearing
screw
piston
cylinder
screws and
washers four cover, joint of co- gearing fork
pper under cober o ring
edges ring
series 160 only
Figure 122
Figure 123
Installation of Satellite Box Blocking Drive

Mechanism Unit 1. Install the locking ring in the drive shaft in
the differential unit. The L from section
of the fork and the hole for the drive shaft
WARNING: should be turned towards the cylinder hou-
Upon applying the silicone chemical joint, a sing side in the differential box. Figure 124
small quantity of acid vapor will be released. In
order to prevent serious per-sonal injury, en-
sure that the work area is well ventilated. Read
the manufacturers instructions before using
the silicone chemical joint, and then follow the
instructions CAUTIONly. If your eyes are at-
tained by the material of the silicone chemical
joint, follow the manufacturers emergency pro-
cedures. Make an appointment with an ophthal-
mologist as quickly as possible.
Be CAUTION when using Loctite adhesive to
avoid serious personal injury. Read the manu-
-facturers instructions before using this pro- L form fork external
duct. Follow the instructions CAUTIONly to surface
prevent irritation of the eyes and skin.
Figure 124
2. Compress the spring of the locking drive
shaft and install it between the rear part of
the locking fork and the inside wall. Figure
125. conic end
drive shaft spring

drive cylinder
Figure 127
Install the spring

behind the fork
Figure 125 7. Apply a continuous fillet of 1.5 mm (0.06) in
diameter of seal for flanges of Loctite with
number ArvinMeritor 2297-D-7076, around
3. Align the spring and the hole of the locking the threads of the DCDL cylinder.
ring fork with the hole of the drive shaft in
8. Turn the piston and drive cylinder unit to the
the differential box.
right until reaching the bottom of the hou-
4. Install the drive shaft through the hole in the sing in the differential box. Figure 128.
differential box, the locking ring fork and the
spring. Figure 126.
gearing ring
fork
drive
shaft
Figure 126 Figure 128
5. If necessary, lubricate a new O ring with 9. Position the locking ring on the fork. The
lubricating oil of the shaft. Install the O ring larger notch of the locking ring should be
in the piston channel. turned towards the main satellite box. Use
6. Install the piston unit with the O ring insi- a rubber hammer to hit the locking ring until
de the drive cylinder with the beveled side it goes through the bosses of the drive fork.
turned towards the bottom of the cylinder. Figure 129.
Push the piston until it is at the bottom of the
cylinder. Figure 127.
10. Engage the notch of the locking ring with 12. With the locking ring in the engaged posi-
the notch of the satellite box. Insert the ma- tion, install the sensor switch in its threaded
nual gearing screw by the top of the drive hole in the front part of the differential box.
cylinder of the mechanism to move the ge- Figure 131.
aring ring in the direction of the satellite box.
Turn the gearing ring as required to align
the notches. Figure 130.
large
notches
in the
satellite
box of the
main diffe-
rential
Figure 131
13. Connect a multimeter to the sensor switch.

bosses in the gearing
Select the resistance measurement function
Figure 129
ring fork in the appliance. With the DCDL engaged,
the circuit should be closed, showing less
11. Turn the manual gearing screw to the right than 1 ohm of resistance. If the resistance
until its head is approximately 6 mm (0.25) is above 1 ohm, check the sensor.
from the cylinder top. Do not turn the screw A. Check that the fork is aligned with the sen-
beyond its normal stop. The screw will have sor switch when it is in the engaged posi-
raised the piston to the correct work position tion.
and the locking system of the main satellite B. Check that the connection wires are loose.
box will be completely engaged. The connector should be firmly placed in its
hous-ing.
Note: C. Check that the sensor switch is totally pres-
The differential unit should be in its locked sed against the differential box.
position t install the half shaft in the shaft If the resistance is greater than 1 ohm
frame. after these checks, replace the sensor
switch.
DCDL Mechanism Unit with Fastening by
Screws.
Install the drive mechanism after the differential
drive cylinder of unit has been assembled and the adjustments
the threaded of the gears and roller bearings are ready.
dcdl The drive mechanism of the type fastened by
screws is shown in Figure 132.
manual gearing screw
Figure 130
DCDL FASTENED BY SCREWS 4. Apply the thread lock Loctite 222 to the
threads of the drive shaft of the locking ring
fork.
5. Install the locking fork in its assembly posi-
tion in the differential box. Figure 134.
1 - Plain washers or chemi- 8 - Engaged

cal joint as required 9 - Copper joint
2 - Cylinder 10 - Pin
3 - Electrical connection for 11 - Gearing ring fork
the sensor
12 - Gearing ring
4 - Air line Figure 134
13 - Drive shaft and spring
5 - O Ring
6 - Piston 6. Maintain the gearing ring fork in its position.
7 - Disengaged Install the return spring of the drive shaft
through the opening for the shaft in the diffe-
Figure 132 rential box, through the fork hole and inside
the housing for the spring. Figure 135.
1. In the differential models with locking ring

fork with elastic pins, install the two elastic
pins at the ends of the fork. Insert the pins Apply Thread
until they are touching the internal side of Chemical Lock 222
the fork. Figure 133. Do not install the pins
in their end position at this moment.
gearing ring fork drive

elastic pin shaft
internal sur-
faces of the Figure 135
fork
Figure 133 7. Slide the drive shaft on the spring. Install

the drive shaft in the locking ring fork. Ti-
ghten with 27-34 N.m (20-25 lb-ft).
2. If the blocking pin of the spring was remo- 8. Install the copper joint or apply the Silas-
ved from the drive shaft head, reinstall the tic seal, with number ArvinMeritor 1199-Q-
pin now. 2981, on the touching surface of the cylin-
3. In the models without the spring blocking der. Figure 136.
pin, assemble the locking fork in its position.
VERSION FASTENED BY SCREWS cylinder
cover
9. Lubricate the O ring with shaft lubricating
oil. Install the O ring in its channel in the screw 4-6
piston. CAUTIONly install the air piston in- lb-ft (6,6-
side the air cylinder. Figure 136. Do not da- 8,6 N/M)
mage the O ring.
10. Install the air cylinder inside the housing in
the differential box. Check that the pilot in
the piston entered the housing of the drive Apply Chemi-
shaft. Figure 137. cal Joint
air
Figure 138
cylinder
13. Slide the gearing ring inside the locking ring
fork and engage the notch of the locking
piston and ring with the notch of the satellite box. Use a
o ring
manual actuation screw to move the locking
ring on the satellite box.
drive
14. Maintain the gearing ring in its locked or en-
shaft
gaged position and hit the two elastic pins at
the ends of the fork until they are level with
Install plain washer or ap- the external surfaces of the fork. Figure 139.
ply chemical joint Figure 136 15 While the locking ring is in its locked posi-
tion, place the sensor switch in the threaded
VERSO FIXADA POR PARAFUSO
hole and with the locking nut loose.
11. Install the copper joint, if used, in the hou-
sing inside the air cylinder cover. Place the
cover in its position on the cylinder so that VERSION
the air inlet is turned upwards when the di-
fferential unit is installed in the shaft frame.
Install the cover with the four setscrews and MANUAL
retaining washers. Tighten the screws with GEARING
5.5-8.5 N.m (4-6 lb-ft). Figure 138. GEARING RING SCREW
GEARING
12. Apply a fillet of Silastic seal, number Arvin- FORK
Meritor 1199-Q-2981, in the joint between
the cylinder and frame of the differential.
cilindro e
pisto Figure 139
piloto
16. Connect a multimeter to the sensor switch.

eixo de Select the resistance function in the applian-
acionamento ce. Turn the switch in the direction of the clo-
ck pointers until you read on the appliance a
resistance infinite or less than 1 ohm. Give
the switch an additional turn and tighten the
locking nut with 35-45 N.m (25-35 lb-ft).
Figure 137
Covers Stopping Up the Satellite Box Blo- Wear safe protection for the eyes;
cking System Wear clothes which protect your skin;
For differentials without the main satellite box Work in a well-ventilated area;
blocking system, assemble a protection cover
Do not use gasoline or solvents which con-
and plug to stop up the hole for the sensor as
tain gasoline. Gasoline can explode;
below.
You will be able to use a hot solution tank
Assembly of the protection cover unit for
or alkaline solution. Read the manufacturers
DCDL fastened by screws.
instructions before using tanks with a hot so-
1. Install the washer and the plug in the threa- lution and alkaline solutions. Then, CAUTIO-
ded hole for the sensor switch. Tighten the Nly follow the instructions.
plug with 60-74 N.m (45-55 lb-ft). Figure 140.
Note:
2. Apply the silicone chemical joint to the as-
sembly surface of the protection cover in the When you install the differential unit in the
differential box. shaft frame, the locking ring should be in
the coupled or engaged position. This can
3. Install the four washers and screws. Tighten
be obtained by applying air pressure to the
the screws with 10-12 N.m (7.4-8.9 lb-ft). Fi-
cylinder or by using the manual gearing
gure 140.
screw. See the procedure in this section.
The differential should be in the engaged or
COVER IN THE VERSION FASTENED BY THREAD coupled position to allow it to be installed
(Apply adhesive Loctite 518 to the cover threads)) in the shaft frame After installing the diffe-
rential unit in the shaft frame, activate the
WASHER WASHER mechanism to the unlocked or disengaged
position to allow the installation of the half
shaft of the left side.
SCREW Manual Method
SENSOR
SWITCH 1. Use cleaning solvent and cloths to clean the
PLUG COVER IN THE
VERSION FASTE- internal part and the assembly surface of the
NED BY SCREWS flange of the differential unit in the shaft fra-
(Apply Chemical me.
Joint)
2. Check the shaft frame to identify if it is dama-
Figure 140 ged. If necessary, repair or replace the shaft
frame.
3. Check if there are tap bolts loose on the as-
Assembly of the protection cover unit for sembly surface of the differential unit. Remo-
DCDL fastened by thread. ve and replace the tap bolts when required.
1. Apply the adhesive Loctite 518 to the protec- Apply adhesive to the threaded holes of the
tion cover threads. tap bolts. Install and tighten the tap bolts with
204-312 N.m (150-230 lb-ft).
Assembly of the Previous Differential Unit
in the Shaft Frame 4. The locking system of the satellite box should
be in the coupled or engaged position before
installing the differential unit in the shaft fra-
me. See the procedure in this section.
WARNING:
5. Install the differential unit in the shaft frame.
Solvents for cleaning can be flammable,
poisonous and cause burns. Examples of 6. Install and tighten the setscrews of the diffe-
solvents for cleaning are: carbon tetrachlo- rential unit in the shaft frame with the torque
ride, emulsion types and solvents with a pe- specified.
troleum base. Read the manufacturers ins- 7. Install the half shafts of the left side and the
tructions before using the cleaning solvent, right side.
and then CAUTIONly follow the instructions.
Also obey the following procedures.
Note: DRIVE MECHANISM OF DCDL FASTENED
When the manual engaging screw is remo- BY THREAD
ved from the service position of the actu-
ator center of the DCDL, the main satellite housing hole
box locking system will be disengaged or
uncoupled.
cylinder
8. Remove the long engaging screw of the
DCDL of the cylinder with fastening by
thread or of the cylinder with fastening by
screws
manual gearing
9. Clean the plug, joint, cylinder cover and the screw
air hose
threaded hole of the cylinder cover center
of the DCDL fastened by screws, or in the
Figure 142
cylinder cen-ter of the DCDL fastened DRI-
VE MECHANISM OF DCDL FASTENED
BY THREAD HOUSING HOLE CYLINDER 13. Connect the air line of the vehicle to the main
Figure 142 MANUALby thread. satellite box blocking drive mechanism.
10. Check that the sealing joint is under the 14. Install the electrical connection in the sen-
screw head. sor switch located in the differential box un-
der the actuator unit.
11. Install the manual gearing screw in its hou-
sing in the versions of the DCDL fastened 15. Remove the safety support under the shaft.
by thread or fastened by screws. Figure 141 Lower the vehicle to the ground.
and Figure 142. 16. Fill the shaft with lubricating oil.
A. In the DCDL fastened by screws, remove 17. Proceed to check the locking system of the
the short plug and the joint of the housing main satellite box as described in this sec-
hole. Install the short plug and joint in the tion.
service hole in the center of the DCDL. Fi- Method with Auxiliary Air Supply
gure 141. 1. Use a cleaning solvent and cloths to clean
B. In the DCDL fastened by thread, install the the internal part of the frame and the as-
short screw or plug in the housing hole loca- sembly flange of the differential unit.
ted in the top of the drive mechanism box. 2. Check the differential frame to identify da-
Figure 142. 12. Tighten the plug with 44-55 mage. If necessary, repair or replace the
lb-ft (60-75 N.m). Tighten the manual gea- shaft frame.
ring screw 30- 38 N.m (22-28 lb-ft) for cylin-
ders of the DCDL fas-tened by screws and 3. Check if there are loose tap bolts in the as-
10-15 N.m (7-11 lb-ft) for mechanisms of sembly flange of the differential unit. Remo-
the reverse type DCDL fastened by thread. ve and replace the tap bolts when re-qui-
red. Apply adhesive to the threaded holes.
DCDL UNIT FASTENED BY SCREWS Install and tighten the tap bolt with 204-312
MANUAL N.m (150-230 lb-ft).
GEARING
4. Connect an air line to the blocking mecha-
SCREW
AIR nism of the main satellite box.
LINE
5. The air line should supply the mechanism
with a regulated pressure of 827 Kpa (120
plug aND JOINT
Psi).
6. Check if the DCDL is engaged or
sensor
HOLE FOR HOUSING POSITION OF THE HOLE

OF THE PLUG AND FOR MANUAL GEARING
JOINT IN THE LOWER SCREW
PART Figure 141
7. Install the differential unit in the shaft frame. 3. Drive the vehicle at 8-16 km/h (5-10 mph)
8. Install and tighten the setscrews of the diffe- and check the light indicating the differential
rential unit with the torque specified. block-ing. The light should be off when the
switch is in the unlocked or disengaged posi-
9. Install the half shaft of the left side and the
tion.
right side.
4. Continue to drive the vehicle and place the
10. Remove the coupling of the air line from the
switch of the differential blocking system in
main satellite box locking mechanism unit.
the locked or engaged position. Take your
11. Clean the plug, joint, cylinder cover and the foot off the accelerator to remove the torque
threaded hole of the cylinder cover center of the cardan shaft and allow the blocking po-
of the DCDL fastened by screws, or in the sition to be changed. The light should be on
cylinder center of the DCDL fastened by when the switch is in the locked position.
thread.
If the indication light continues to be ON with
12. Tighten the plug with 60-75 N.m (44-55 lb- the switch in the unlocked position, the blo-
-ft). Tighten the manual engagement screw cking system is still in the locked position.
with 30-38 N.m (22-28 lb-ft) of the cylinders Check if the manual gearing screw has been
of the DCDL fastened by screws and 10-15 removed from the cylinder cover of the drive
N.m (7-11 lb-ft) for the DCDL type fastened mechanism of the differential blocking. See
by thread. the o procedure in this section.
13. Connect the air line of the vehicle to the dri- Label of Driver Care with the
ve mechanism of the main satellite box blo-
DCDL Check if the driver care label is instal-
cking.
led in the vehicle cabin. Figure 143. The label
14. Install the electrical connection to the sen- should be placed in a place easy to be seen by
sor switch located in the differential box be- the driver. The recommended place is on the
low the actuator unit. instrument panel, next to the indication lamp
15. Remove the safety support under the shaft. and differential locking switch.
Lower the vehicle to the ground.
16. Fill the shaft with lubricating oil.
17. Proceed to check the main satellite box
blocking system as described in this
section.
Checking the Main Satellite Box Blocking ! CAREFUL

System. This vehicle is equipped with a Shaft Blocking System,
1. Place the transmission of the vehicle in the controlled by the driver. (DCDL)
disengaged position. Turn on the engine so Only use the DCDL in poor road conditions
that the pneumatic system of the vehicle at- Do not activate when descending
tains the normal pressure level of functioning. Do not activate the blocking in speeds above 40 Km/H
W hen the blocking is activated, the vehicle may be uncomfor-
table to drive, which requires care in the procedure of opera-
ting the vehicle. When the blocking is deactivated, the driving
WARNING: conditions return to normal.
During the disassembly of the DCDL, when
For further information about using the blocking, see
it is in the locked or engaged position and the vehicle operators manual
one of the wheels is off the ground, do not
turn on the engine or couple the transmis-
sion. The vehicle may move and cause se-
rious personal injury and damage to the
components.
2. Place the drive switch of the differential blo-
cking installed in the vehicle cabin in the un-
locked or disengaged position.
The use of incorrect lubricants or those with
unsuitable additives is, usually, the greatest
cause of failures occurring in differentials.
The lubricating oil specified for the differential
must have features of extreme pressure (EP),
service classification API-GL- 5 of the Ame-
rican Petroleum Institute and meet the requi-
rements of the American military specification
MILL-2105-C.
This type of oil, better known as hypoid oil, has
a lubricating film capable of supporting high
work load pressure, which makes it appropriate
for hypoid gears, where the lubrication condi-
-tions are rather severe.
Viscosity
Generally speaking, the high viscosity degree
of monoviscous oil is suited to high ambient
temperatures. Besides extending the useful life
of the gears, opting for a multiviscous oil will
satisfy the temperature conditions found. The
table below represents the viscosity selection
of oils:
MILITARY AMBIENT TEMP.

OIL DESCRIPTION
SPECIFIC. MIN. MAX.
MIL - L2105 - C/D API GL-5 85W/140 -12 C -X-
MIL - L2105 - C/D API GL-5 80W/140 -15 C -X-
MIL - L2105 - C/D API GL-5 80W/140 -28 C -X-
MIL - L2105 - C/D API GL-5 75W/140 -40 C -X-
MIL - L2105 - C/D API GL-5 75W/140 -40 C -X-
MIL - L2105 - B API GL-5 90 0 C -X-
MIL - L2105 - B API GL-5 140 +4 C -X-
Lubrication
Inspection and Recommendations Change the oil every 160,000 km or once a

year, whichever occurs first.
Every 2000km check that the oil level is correct.
Vehicles which operate on the highway or off
Execute the drainage operation while the oil is the road in severe applications, using the maxi-
still warm. This allows the lubricant to flow free- mum load capacity allowed, should change the
ly and more quickly, reducing the time required oil at intervals of 40000 - 50000 km, or every six
to drain the oil completely from the differential. months, whichever occurs first.
Complete the level or resupply until the lubri-
cant runs slightly over the lower edge of the oil
level filling hole. Magnetic Plug
The shaft should not be washed internally with MERITOR recommends using magnetic plugs
any type of solvent (kerosene, gasoline, diesel in the oil drainage hole of the shaft.
oil, etc.).
After each oil change, and before placing the IMPORTANTE:
vehicle in normal operation, drive limiting the
The magnetic plug quickly loses its effi-
speed to 40 km/h, for 5 to 10 minutes, or 2 to 3
ciency when it accumulates many metallic
km to ensure that all the channels and pockets
particles, and, therefore, should be cleaned
were duly filled with the lubricating oil.
before losing its efficiency. The removed
f the differential is a replacement unit, not fore- plug can be cleaned and reused. It is ad-
seen for immediate reuse, all the bearings and visable to practice this procedure once or
gears should be covered with a good layer of many times within the period of changing
anticorrosive oil. the oil.
In this case, the differential should be main-
tained in a closed box until its reuse, to avoid
contact between dust and other impuri-ties and
the unit.
Change Periods
New or Reconditioned Units. In the initial period
(running in), change the oil of the differential be-
tween 2000 and 5000 km. This initial change is
recommended to ensure the removal of metallic
particles, usually released in a greater quantity
during this phase.
After the Running In Period Vehicles which

operate basically on highways, with work loads
below their maximum capacity of load allowed.
MAINTENANCE MANUAL
TORQUE SPECIFIED N.m (lbf.P)
ITEM DESCRIPTION
RS 120 145/147 155 160 185
1 Pinion nut 1006-1250 (740-920) 1250-1535 (920-1130) 1250-1535 (920-1130) 1350-1670 (1000-1230) 1350-1670 (1000-1230)
2 Screw (fastening pinion box) 95-150 (70-110) 95-150 (70-110) 91-150 (67-91) 95-150 (70-110) 95-150 (70-110)
3 Screw (fastening satellite box) 129-156 (95-115) 130-155 (95-115) 235-290 (175-214) 300-420 (220-310) 300-420 (220-310)
4 Filling hole and oil level 47 mn. (35 mn) 47 mn. (35 mn.) 47 mn. (35 mn.) 47 mn. (35 mn.) 47 mn. (35 mn.)
5 Screw (fastening bearing) 245-299 (180-220) 430-540 (320-400) 575-705 (425-520) 650-810 (480-600) 650-810 (480-600)
6 Nuts (fastening crow) 150-177 (110-130) 220-290 (160-210) 300-365 (220-270) 265-355 (195-262) 365-355 (195-262)
7 Draining plug 47 mn (35 mn.) 47 mn. (35 mn.) 47 mn. (35 mn.) 47 mn. (35 mn.) 47 mn. (35 mn.)
8 Breathing plug 2,3 - 2,8 (20-25) 2,3-2,8 (20-25) 27 mn. (20 mn.) 27 mn. (20 mn.) 27 mn. (20 mn.)
59
Torque Table
Always use Technical Manuals of...
MAINTENANCE MANUAL
Always use original parts
For more details, see the Spare Parts Catalog
Customer service
55 11 3684.6741
55 11 3684.6867
Purchase the CD-ROM failure analysis of components of the axis

traction
Customer Service
Av. Joo Batista, 825 - Osasco - SP - 06097-105
Tel. (11) 3684-664 - (11) 3684-6867
AfterMarket (Replace parts)

R. Ester Rombenso, 403 - Osasco - SP - 06097-120
Tel. (11) 0800-555530
www.arvinmeritor.com

Eixo Dif Simples Vel ENG

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Eixo Dif Simples Vel ENG

Загружено:

Авторское право:

Доступные форматы

MAINTENANCE MANUAL

Axle Single-Reduction Differential

01 Differential Box 31 Roller Bearing Cone (Inside Pinion)

AXLE UNIT ID PLATE

Remove the half shafts.

Removal of the Differential

D - Measure the value of the gearing gap of

B - Loosen the retaining washers and screws

E - Remove the satellite box with safety and

C - Separate the two halves of the box and re-

F - If it is necessary to replace the crown and it

D - If necessary, loosen and remove the retai-

C - Remove and discard the pinion sealer (figu-

D - Loosen the setscrews of the pinion box and

M - Remove, if necessary, the pilot roller bea- CAUTION:

Inspection of the Roller Bearings

6 - Splintering or scaling in the surface of the

Inspection of the Unit Satellite Box

Inspection of the Differential Box

Inspection of the Universal Joint Fork

A - Replace the nuts and bolts with rounded ed-

FEATURES OF THE LIQUID LOCKS

PRODUCT TYPE COLOR CURE TIME TORQUE

THREE 1334 RED 6 HOURS MEDIUM

B - Tighten the fastening components with the

B - After the application, join the two surfaces

C - Assemble the pilot roller bearing, using a

120 2,2 - 3,3 20 - 30 1,3 - 2,0 12 - 18

145/147 0,5 - 5,0 5 - 45 1,1 - 3,4 10 - 30

155 1,7 - 4,0 15- 35 1,1 - 2,3 10- 20

160 0,5 - 5,0 5 - 45 1,1 - 3,4 10 - 30

185 0,5 - 5,0 5 - 45 1,1 - 3,4 10 - 30

MODEL RS 120 MODEL 145/147

MODEL 155 MODEL 160 / 185

RECOMMENDED RANGE IMPORTANT:

C - Wind a cord around the pilot diameter Note :

H - If after tightening with the maximum limit of

- With the aid of Special Tool 140 / 145

Install the pinion box with the surface which will

Place four bolts and apply a start tightening in a

MODEL (CN) NOMINAL GAUGE

Figure 63 120 193,68

1. Recording (0) zero at the top of the pinion.

A - Measurement obtained in the clock reading; Method without Special Tool

5 Adjustments of Differential Action: Add 0.009 to the original wedge

A - Identification of the Pinion Box Adjustment THICKNESS

B - Nominal dimension of pinion assembly:

b - Press the pinion sealer with a coupling or

B - Install the pinion box. If necessary use a

120 2,2 - 3,3 20 - 30 1,3 - 2,0 12 - 18

145/147 0,5 - 5,0 5 - 45 1,1 - 3,4 10 - 30

155 1,7 - 4,0 15- 35 1,1 - 2,3 10- 20

185 0,5 - 5,0 5 - 45 1,1 - 3,4 10 - 30

E - Assemble the new cones of the roller bea-

C - Install the crown in the flange half of the sa-

F - Position the planetary gear with its thrust

H - Then position the planetary gear opposite

I - Install the satellite box single half, ob-ser-

D - Place a torquemeter at the end of this device

A - Place a protector in the vise (filing block) of

E - If the value exceeds that specified, disas-

Assembly of the Satellite Box/Adjustment

B - Place the adjusting rings in the bearings tur-

ring side ring opposite