Diagnóstico Meritor

TP-99125
Issued 12-99
Forward and Rear Axle

Carrier Diagnostic
Flowcharts
TECHNICAL BULLETIN
Introduction
How to Use This Publication

Introduction
Performing the Diagnostic
Refer to the following diagnostic flowcharts to help Procedures in This Bulletin
you determine the source of axle differential
Refer to the following publications when you
carrier complaints.
perform the diagnostic procedures in this bulletin.
Before you use the flowcharts, investigate the axle
r Lubrication
carrier complaint and confirm that the problem
Maintenance Manual No. 1
involves the carrier.
r Single Reduction Differential Carriers
To locate the correct flowchart, refer to the
Maintenance Manual No. 5
following tables.
r Single Reduction Rear Differential Carriers
Forward Tandem Carrier Maintenance Manual No. 5A
Flowchart Page r Tandem Axle Forward Carriers and Single Axle

Carriers — Maintenance Manual No. 5E
Vehicle Will Not Move 2
r Single Reduction Forward Differential Carriers
Differential Making Noise 4 on Tandem Axles — Maintenance Manual No. 5L
Oil Leak 6 r Failure Analysis for Drive Axle Components

Manual No. TP-9955
To order copies of these publications or a CD
Rear Tandem or Single Carrier version of the diagnostic flowcharts (TP-99113),
call Meritor’s Customer Service Center at
Flowchart Page 800-535-5560.
Vehicle Will Not Move 7
Differential Making Noise 8
Oil Leak 9
All Rear Axles
Flowchart Page
Contaminated Lubricant Found
During Preventive Maintenance 10
TP-99125
Issued 12-99 16579/24240
Page 1 © Copyright Meritor Automotive, Inc., 1999 Printed in the USA
Forward Tandem Carrier
Vehicle Will Not Move
Forward
Vehicle Will
Tandem
Not Move
Carrier
Visually inspect
the carrier
in the axle Check for further carrier
housing. damage. If none is found,
Damaged or Yes repair or replace the oil
contaminated? pump, clean or replace the
Remove the
carrier from the oil screen and install the
axle housing. carrier. Refer to MM 5L.
Yes
Damaged? Repair the carrier No
or install a
remanufactured Inspect the inter-axle differential
No carrier. assembly for damage. Refer to
TP-9955, Failure Analysis for
Drive Axle Components.
Drain and inspect
the lubricant.
Refer to MM 1. Check for further carrier
damage. If none is found,
Yes replace the damaged
Damaged? inter-axle differential
components and install the
carrier. Refer to MM 5L.
Determine the No
Yes
Contaminated? source of
contamination.
Inter-axle
Welded differential case
No bolted or
welded?
Remove the Bolted

carrier from
Inspect the pinion
the housing.
gears and spider. Disassemble the
Refer to MM 5L.
Refer to TP-9955, inter-axle
Failure Analysis differential case.
for Drive Axle
Components.
Visually inspect the ring

pinion gear set for Inspect the inter-axle differential
damage. Refer to TP-9955, spider, side gears, thrust washers
Failure Analysis for and bearings. Refer to TP-9955,
Drive Axle Components. Failure Analysis for Drive
Axle Components.
Check for further carrier

Repair the carrier damage. If none is found,
or install a replace the inter-axle
Yes
Damaged? remanufactured differential components
Yes and install the carrier. If
carrier. Damaged?
Refer to MM 5L. the inter-axle differential
No case is welded, replace
the entire inter-axle
differential case.
No
Remove and Refer to MM 5L.
disassemble the input
shaft and Inspect the main differential
inter-axle differential bearings for damage.
assembly. Refer to MM 5L. Refer to TP-9955,
Failure Analysis for
If the carrier is a pump model,

inspect the input shaft oil Repair the carrier
pump for damage and the oil Yes or install a
screen for contamination. Refer Damaged? remanufactured
to TP-9955, Failure Analysis for carrier.
Drive Axle Components. Refer to MM 5L.
No
Check the ring gear backlash

and record the reading.
Refer to MM 5L. Use the
backlash reading when
you reassemble the carrier.
This flowchart continues

on the next page.
TP-99125
16579/24240 Issued 12-99
Printed in the USA © Copyright Meritor Automotive, Inc., 1999 Page 2

from the previous page.
When the carrier is When the carrier is

reassembled later, reassembled later, If damaged, repair the
Yes Backlash No input shaft, inter-axle
set the backlash set the backlash
within spec? differential, side gears or
to the recorded to spec. Refer to
reading. MM 5L. bearings. Install the input
shaft. Refer to MM 5L.
Remove the main
differential and
ring gear from
the carrier. Install a new
Refer to MM 5L. unitized seal.
Inspect the main differential

bearings for damage. Refer Set the input
to TP-9955, Failure Analysis shaft end play to
for Drive Axle Components. the correct
specification.
Refer to MM 5L.
Repair the carrier
Yes or install a
Damaged? remanufactured
carrier.
Refer to MM 5L. Install the carrier.
No
Refer to MM 5L.
Test drive the vehicle.
Disassemble the Return the vehicle to service.
main differential.
Refer to MM 5L.
Inspect the main

differential case, side gears
and spider for damage.
Refer to TP-9955,
Failure Analysis for Drive
Axle Components.
Repair the carrier

Yes or install a
carrier.
Refer to MM 5L.
No
Inspect the drive pinion,

inner drive pinion bearing
and spigot bearing for damage.
Refer to TP-9955, Failure
Analysis for Drive
Axle Components.
Repair the carrier

Yes or install a
carrier.
Refer to MM 5L.
No
Reassemble and
install the main
differential.
Refer to MM 5L.
Reset the backlash.

Refer to MM 5L.
TP-99125
16579/24240 Issued 12-99
Differential Making Noise
Forward
Differential
Tandem
Making
Carrier
Noise
Visually inspect
the carrier in
the axle housing.
Remove the Damaged or Yes repair or replace the
carrier from the contaminated? oil pump, clean or replace
Yes axle housing.
Damaged? the oil screen and install
Repair the carrier
the carrier. Refer to MM 5L.
or install a
remanufactured No
No carrier.
Inspect the inter-axle

Check the input differential assembly for
shaft end play. damage. Refer to TP-9955,
Refer to MM 5L. Failure Analysis for Drive
Axle Components.
Set the input Check for further carrier

Inspect the damage. If none is found,
End play No shaft end
lubricant. Yes replace the damaged
within spec? play to spec.
Refer to MM 1. Damaged? inter-axle differential
Refer to MM 5L.
Yes carrier. Refer to MM 5L.
No
Drain and inspect Yes
the lubricant. Contaminated?
Refer to MM 1.
Inter-axle
Welded differential case
No
bolted or
welded?
Fill the carrier with
Yes Determine
Contaminated? the correct amount
the source of of the specified Inspect the Bolted
contamination. lubricant. Refer to pinion gears
MM 1. Test drive and spider.
No
the vehicle. Refer to Disassemble
Remove the carrier TP-9955, the inter-axle
from the housing. Failure differential case.
Refer to MM 5L. Yes Analysis for
Noisy? Drive Axle
Components.
No
Inspect the inter-axle
Visually inspect the ring
Return the differential spider, side gears,
gear and pinion for
vehicle to thrust washers and bearings.
damage. Refer to TP-9955,
service. Refer to TP-9955,

Repair the carrier
Yes or install a
Damaged? Yes replace the damaged
remanufactured Damaged? inter-axle differential
carrier.
Refer to MM 5L.
No carrier. Refer to MM 5L.
No
Remove and
Inspect the main
disassemble the input differential bearings for
shaft and inter-axle damage. Refer to TP-9955,
differential assembly. Failure Analysis for Drive
Refer to MM 5L.
Axle Components.
Repair the carrier

Inspect the input shaft or install a
oil pump for damage Yes
and the oil screen for carrier.
contamination. Refer to Refer to MM 5L.
TP-9955, Failure No
Analysis for Drive Axle
Components. Check the ring gear
backlash and
record the reading.
Refer to MM 5L.

on the next page.
TP-99125
16579/24240 Issued 12-99

from the previous page.
When the main When the main

differential is differential is Reassemble and install
reassembled later, Yes Backlash No reassembled later, set the main differential.
set the backlash to within spec? the backlash to spec. Refer to MM 5L.
the recorded reading. Refer to MM 5L.
Remove the main

differential and Reset the backlash.
ring gear from Refer to MM 5L.
the carrier.
Refer to MM 5L.
If damaged, repair the

input shaft, inter-axle
differential, side gears
Inspect the main differential
or bearings. Install the input
bearings for damage.
shaft. Refer to MM 5L.
Analysis for Drive Axle
Components.
Install a new
unitized seal.
Repair the carrier
Yes or install a
carrier.
Refer to MM 5L. Set the input shaft
No end play to the
correct specification.
Refer to MM 5L.
Disassemble the
main differential.
Refer to MM 5L.
Install the carrier.
Refer to MM 5L.
Return the vehicle to service.
Inspect the main
differential case, side
gears and spider for
damage. Refer to TP-9955,
Failure Analysis for Drive
Axle Components.
Repair the carrier

Yes or install a
carrier.
Refer to MM 5L.
No
Inspect the drive pinion,

inner drive pinion
bearing and spigot bearing
for damage. Refer to
TP-9955, Failure Analysis
for Drive Axle Components.
Repair the carrier

Yes or install a
carrier.
Refer to MM 5L.
No
TP-99125
16579/24240 Issued 12-99
Oil Leak
Forward
Oil Leak Tandem Carrier
Visually inspect
the carrier in the
axle housing.
Drain and inspect
Remove the carrier the lubricant.
from the axle housing. Refer to MM 1.
Yes Repair the carrier or
Damaged? install a
remanufactured
carrier. Refer
No to MM 5L. Remove the carrier
from the axle housing.
Refer to MM 5L.
Inspect the
breather.
Clean and prepare

the housing and
carrier flanges.
Apply the correct
Clean or replace the
Yes gasket or silicone.
Breather breather. A clogged
Refer to MM 5L.
clogged? breather can cause
a seal leak.
No
Refer to MM 5L.
Inspect the
input shaft seal
for leaks.

the correct amount
of the specified lubricant.
Seal Yes Replace the input Refer to MM 1.
leaking? shaft seal with
a unitized seal.
No
Test drive the vehicle
Fill the carrier with to confirm that the
the correct amount leak is repaired. Return
Inspect the ouput
of the specified the vehicle to service.
shaft seal for
lubricant.
leakage.
Refer to MM 1.
Clean the seal area.
Replace the output

shaft seal with Yes Seal
a unitized seal. leaking? Test drive the vehicle
to confirm that
No the leak is repaired.
Return the vehicle
to service.
Fill the carrier with the
correct amount of the Inspect the
specified lubricant. carrier-to-housing
Refer to MM 1. joint for leaks.
Inspect the axle

housing welds for
Test drive the vehicle Joint No cracks or leaks. If you
to confirm that the leaking? find weld cracks, contact
leak is repaired. Return Meritor for repair
the vehicle to service. welding procedures.
Yes
TP-99125
16579/24240 Issued 12-99
Rear Tandem or Single Carrier
Rear
Vehicle
Tandem
Will Not
or Single
Move Carrier
Visually inspect
the carrier in
the axle housing.
reassembled later, Yes Backlash No reassembled later, set
Remove the within spec?
set the backlash to the backlash to spec.
carrier from the
the recorded reading. Refer to MM 5.
axle housing.
Yes
Damaged? Repair the carrier
or install a Remove the main
remanufactured differential and
carrier. Refer ring gear from
No the carrier.
to MM 5.
Refer to MM 5.
Drain and inspect
the lubricant.
Refer to MM 1. Inspect the main differential bearings
for damage. Refer to TP-9955, Failure
Analysis for Drive Axle Components.
Yes Determine
Contaminated? the source of Repair the carrier
contamination. Yes or install a
No carrier.
Refer to MM 5.
No
Check the drive pinion end play.
Refer to MM 5. Any end play Disassemble the main differential
looseness indicates possible and ring gear. Refer to MM 5.
bearing damage.
Inspect the main differential case, side gears

and spider for damage. Refer to TP-9955,
Remove the carrier
Failure Analysis for Drive Axle Components.
Refer to MM 5.
Repair the carrier
Yes or install a
Visually inspect the ring Damaged? remanufactured
gear and pinion for carrier.
damage. Refer to Refer to MM 5.
TP-9955, Failure No
Analysis for Drive
Axle Components. Inspect the drive pinion, inner drive
pinion bearing and spigot bearing for
damage. Refer to TP-9955, Failure
Repair the carrier
Yes or install a
Repair the carrier
carrier.
Yes or install a
Refer to MM 5.
carrier.
Inspect the differential Refer to MM 5.
case bearings for damage. No
Analysis for Drive Axle Reassemble and install
Components. the main differential.
Refer to MM 5.
Repair the carrier

Yes or install a Reset the backlash.
Damaged? remanufactured Refer to MM 5.
carrier.
Refer to MM 5.
No
Install a new
Check the ring gear unitized seal.
backlash and record
the reading. Refer to MM 5.
Use the backlash reading when
you reassemble the carrier. Install the carrier.
Refer to MM 5.
TP-99125
16579/24240 Issued 12-99
Rear
Differential
TandemMaking
or Single
Noise
Carrier
Visually inspect
the carrier in
the axle housing.
reassembled later, Yes Backlash No reassembled later,
Remove the carrier set the backlash to within spec? set the backlash to
from the axle housing. the recorded reading. spec. Refer to MM 5.
Repair the carrier
Yes or install a
Damaged? Remove the main
remanufactured differential and
carrier. ring gear from
No Refer to MM 5. the carrier.
Refer to MM 5.
Drain and inspect

the lubricant.
Refer to MM 1. Inspect the main differential bearings
for damage. Refer to TP-9955, Failure
Repair the carrier

Determine Yes or install a
Yes Damaged? remanufactured
Contaminated? the source of
contamination. carrier.
Refer to MM 5.
No
No
Disassemble the
Check the drive pinion main differential
end play. Refer to MM 5. and ring gear.
Any end play looseness Refer to MM 5.
indicates possible
bearing damage.
Inspect the main differential case, side gears
and spider for damage. Refer to TP-9955,
Remove the carrier from the
axle housing. Refer to MM 5.
Repair the carrier
Yes or install a
Visually inspect the ring gear carrier.
and pinion for damage. Refer to Refer to MM 5.
TP-9955, Failure Analysis for No
Inspect the drive pinion, inner drive pinion bearing
and spigot bearing for damage. Refer to TP-9955,
Repair the carrier
Yes or install a
Damaged? remanufactured Repair the carrier
carrier. or install a
Refer to MM 5. Yes
carrier.
Refer to MM 5.
Inspect the differential No
bearings for damage. Refer to
TP-9955, Failure Analysis for
Reassemble and install the main
differential. Refer to MM 5.
Repair the carrier

Reset the backlash.
Yes or install a
Refer to MM 5.
carrier.
Refer to MM 5.
No
Install a new
unitized seal.
Check the ring gear
backlash and record the
reading. Refer to MM 5.
Use the backlash reading when Install the carrier. Refer to
you reassemble the carrier. MM 5. Test drive the vehicle.
TP-99125
16579/24240 Issued 12-99
Oil Leak
Rear
Oil Leak
Tandem or Single Carrier
Visually inspect
the carrier in
the axle housing.
Clean and prepare the
housing and carrier
Remove the carrier flanges. Apply the correct
from the axle housing. gasket or silicone.
Yes Repair the carrier Refer to MM 5.
Damaged? or install a
remanufactured
carrier.
No Refer to MM 5.
Refer to MM 5.
Inspect the
breather.

the correct amount
Clean or replace the of the specified lubricant.
Breather Yes breather. A clogged Refer to MM 1.
clogged? breather can cause
a seal leak.
Test drive the vehicle to

No
confirm that the leak is
repaired. Return the
Inspect the vehicle to service.
pinion seal
for leaks.
Seal Yes Replace the pinion

leaking? seal with a
unitized seal.
No
Fill the carrier with the

Inspect the correct amount of the
carrier-to-housing specified lubricant.
joint for leaks. Refer to MM 1.
Inspect the axle housing

welds for cracks or leaks. No Joint Test drive the vehicle
If you find weld cracks, leaking? to confirm that the
contact Meritor for repair leak is repaired.
welding procedures. Return the vehicle to
Yes
service.
Drain and inspect

the lubricant.
Refer to MM 1.
Remove the carrier

Refer to MM 5.
TP-99125
16579/24240 Issued 12-99
All Rear Axles
Contaminated Lubricant Found During Preventive Maintenance
All Rear AxlesLubricant Found During Preventive Maintenance
Contaminated
Visually
inspect the
lubricant.
Clean and prepare the

Indicates Milky, housing and carrier
Indicates flanges. Apply the correct
that water Brownish Silvery
Lubricant metallic gasket or silicone.
is entering
color? contamination. Refer to MM 5 or 5L.
the axle.
Send out a lubrication

sample for analysis. Install the carrier.
Inspect the Advise the owner to Refer to MM 5.
breather. return for the results.

If analysis results the correct amount
Clean or replace the
Breather Yes indicate wear or of the specified lubricant.
breather. A clogged
clogged? breakdown in the carrier, Refer to MM 1.
breather can cause
refer to the “Differential
a seal leak.
Making Noise” diagnostic
flowchart in this publication.
No
Test drive the vehicle
Inspect the to confirm that the
carrier seals leak is repaired. Return
for leaks. the vehicle to service.
Seal No Inspect the

leaking? carrier-to-housing
joint for leaks.
Yes
Inspect the axle housing

Replace the leaking Joint No welds for cracks or leaks.
seal with a leaking? If you find weld cracks,
unitized seal. contact Meritor for
repair welding procedures.
Yes
Fill the carrier Drain and

with the correct inspect the
amount of the lubricant.
specified lubricant. Refer to MM 1.
Refer to MM 1.
Remove the
carrier from
Test drive the the axle. Refer to
vehicle to confirm MM 5 or 5L.
that the leak is
repaired. Return the
vehicle to service.
TP-99125
16579/24240 Issued 12-99
Meritor Heavy Vehicle Systems, LLC Information contained in this publication was in effect at the time the publication was approved for printing and is
2135 West Maple Road subject to change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the
Troy, MI 48084 USA information presented or discontinue the production of parts described at any time.
800-535-5560
www.meritorauto.com f Copyright 1999 TP-99125
Meritor Automotive, Inc. Issued 12-99
All Rights Reserved Printed in the USA 16579/24240

Diagnóstico Meritor

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TP-99125

Forward and Rear Axle

How to Use This Publication

Flowchart Page r Tandem Axle Forward Carriers and Single Axle

Oil Leak 6 r Failure Analysis for Drive Axle Components

All Rear Axles

Remove the Bolted

Visually inspect the ring

Check for further carrier

If the carrier is a pump model,

Check the ring gear backlash

This flowchart continues

This flowchart continues

When the carrier is When the carrier is

Inspect the main differential

Inspect the main

Repair the carrier

Inspect the drive pinion,

Repair the carrier

Reset the backlash.

Inspect the inter-axle

Set the input Check for further carrier

Check for further carrier

Repair the carrier

This flowchart continues

This flowchart continues

When the main When the main

Remove the main

If damaged, repair the

Repair the carrier

Inspect the drive pinion,

Repair the carrier

Clean and prepare

Fill the carrier with

Replace the output

Inspect the axle

Inspect the main differential case, side gears

Repair the carrier

Drain and inspect

Repair the carrier

Repair the carrier

Fill the carrier with

Test drive the vehicle to

Seal Yes Replace the pinion

Fill the carrier with the

Inspect the axle housing

Drain and inspect

Remove the carrier

Clean and prepare the

Send out a lubrication

Fill the carrier with

Seal No Inspect the

Inspect the axle housing

Fill the carrier Drain and

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