Meritor Axle & Brake Service Manual
Contents
1. Adjust or repair as required 6 Shimmey or brake pull Refer to 1 2 and 6 Refer to 1 2 and Refer to 1 2 and 6 Rotor run out and thickness variation Replace hub and rotor assembly amp Service 2 4 PAD REMOVAL AND REPLACEMENT The pads must be replaced at or before the amount of pad materials reaches a thickness of 3mm WARNING Caution should be exercised in handling both asbestos and non asbestos materials CAUTION Replace the pads on both brakes of a single axle or all six brakes of a triaxle at the same time If you do not replace all the pads at the same time poor brake performance may occur 1 Put blocks in front and behind the wheel so that the vehicle cannot roll WARNING Do not work under a vehicle supported only by jacks Jacks can slip or fall over and cause serious personal injury Support the vehicle with safety stands Block the wheels to prevent the vehicle from moving A visual pad wear indicator is incorporated into the brake which provides a quick and simple method of assessing the pad life remaining In a new pad condition the end of the indicator stem will extend past the edge of the housing casting Fig 6 As the pads wear the length of indicator visible past the edge of the casting will reduce FIG 6 The indicator is marked with each increment equating to a level of pad wear Fig 7 2 Apply air pressure and fully charge the system to2. 2 6 REMOVAL AND REPLACEMENT 4 Using an 30 A F socket tighten the 6 bolts using the torque and angle sequence specified in Table 1 Fig 18 Removing the Caliper Assy 1 Follow step 1 5 of the Pad Removal and Replacement section 2 4 to remove the pads 2 Remove the air chamber by removing the two chamber mounting nuts and lifting away the air chamber Fig 16 FIG 18 IMPORTANT Ensure torque and angle procedure is adhered to in order to achieve final tightening requirement Fig 19 FIG 16 3 Remove the six caliper mounting bolts Fig 17 WARNING Take care not to allow the caliper to fall Remember the caliper has a weight of 45kg FIG 17 4 Lift the caliper away from the rotor Installing the Caliper Assembly 1 Lift the caliper over the rotor 2 Align the caliper bolt holes and hand start one of the inner fasteners fitted with a hardened washer 3 Hand start the remaining 5 bolts starting on the top half of the torque plate TA amp TAC Service 5 Mount the air chamber onto the caliper assembly ensuring the spherical end of the push rod engages into the spherical socket on the caliper Ensure the chamber is positioned such that the air inlet ports are orientated correctly This is dependant on the suspension type Full installation options are available from Meritor Technical Sales Assemble the supplied washer and nut to the two protruding studs on
3. When the brake is applied the air chamber applies a load to the operating shaft lever arm thus rotating the operating shaft and adjuster assembly taking up the pre set clearance As the operating shaft rotates further the hardened rollers which sit in half bearings in the operating shaft act against the two tappet assemblies and thus generate movement of the tappet assemblies in a linear direction This movement generates a clamp force which is transmitted by the tappet heads evenly across the inner disc pad forcing it against the brake disc The reaction force generated causes the housing to slide on the guide sleeves bolted to the carrier and clamp the outer pad against the disc When the pads contact the disc the clamp load generated in the tappet assemblies rises rapidly This results in a rise in the torque required to rotate the tappet gears This torque lever overcomes the friction between the multi plate clutch assembly causing the clutch plates to slip and therefore preventing any un necessary adjustment When the brakes are released the return spring in conjunction with the actuator return the operating mechanism to its original brakes off position Brake Application with automatic adjustment The actuator operates in the same manner as described above and takes up the backlash clearance in the adjuster Because the clearance between pads and disc is greater than the pre set running clearance no load is generated to cause t
4. the ground Charge the system with air NOTE Before driving the vehicle or applying the park brake apply the service brake five times at low pressure to ensure correct adjustment of the pads 50 Wear 75 Wear 25 Wear Maximum Wear 18 EEE TEN 727 P OSI Win FIG 13 TA amp Service 2 5 ROTOR INSPECTION Rotors should be examined in situ whenever the brakes are serviced or new pads are fitted or immediately if erratic braking performance is noted The rotor condition should be visually checked for the following surface conditions and replaced with a new rotor if suspect or defective A Surface Crazing Fig 14 Light short random crazing surfaces are normal and acceptable B Radial Cracks Fig 14 Short light cracks up to 0 5mm in width and a maximum of 1 0mm in depth are acceptable providing they do not extend radially across more than 75 of the braking surface C Tangential Scoring Fig 14 A series of light circular grooves is normal and permissible if the maximum depth of the grooves is 0 5mm Severe grooving indicated that skimming of the rotor is required providing the minimum thickness of the rotor can be maintained see skimming Wear and grooving should be approximately equal on both surfaces If the wear patterns differ significantly the brake is not functioning correctly and should be examined D Heat Spotted Rotor Fig 1
5. 3 16 4 Fit the two button head screws to the locknut and tighten evenly until both the heads are flush with the face of the locknut Ensure the screws correctly engage into the holes in the lockwasher NOTE The button head screws include a nylon thread locking patch The locking properties of this patch are effective for two further applications of the screw after initial factory assembly The screws should then be replaced 3 16 5 Tighten the two button head screws to the torque value specified in table 1 using a 5mm A F Allen socket and torque wrench Fig 11 FIG 11 TA amp TAC Service ze 3 17 CHECK BEARING ADJUSTMENT TAC Hub Removal Procedure Check for free rotation of the hub assembly and ensure the bearing The TAC hub and bearing assembly is fully sealed and normally does clearance is not excessive not require maintenance However the TAC axle fitted with Q or Z drum If in doubt repeat procedure 3 16 brakes features an inboard mounted brake drum Thus requiring the hub assembly to be removed for brake service 3 18 REFIT HUB CAP The following procedures can be performed either with the road wheel Check the hub face is clean Fit the hub cap gasket Fig 12 and hub assembled to the hub and drum or with the road wheel removed cap 3 19 REMOVAL OF HUB CAP Remove the five M8 hub cap screws Remove the hub cap and gasket Fig 14 FIG 12 Tighten the bolts evenly Finally tighten the hub cap screws t
6. Hub cap amp screws 1 yr 100 000 km Oil Seal Mechanical failure only 1 yr 100 000 km Hub cap amp screws 3 yr 300 000 km TA hub assembly 3 yr 300 000 km Axle end fixings 1 100 000 km Hub cap gasket Mechanical failure only Quick Warranty Reference Chart D Duco Disc Brake for TA Axle Any component not referred to below is covered by 1 100 000 km warranty for mechanical failure only Labour costs can only be claimed at an agreed rate with Meritor Service Department prior to work commencing For full warranty terms and conditions see Meritor Warranty Terms and Conditions Publication No 4 84 1 2 yrs Caliper assembly 1 yr 100 000 km Brake retaining clips 1 yr 100 000 km Brake pad assemblies Mechanical failure only 1 100 000 km ABS components 2yr Brake rotor Mechanical Failure only an ArvinMeritor brand Quick Warranty Reference Chart TA Axle shown Any component not referred to below is covered by a 1 yr 100 000 km warranty for mechanical failure only Labour costs can only be claimed at an agreed rate with Meritor Service Department prior to work commencing For full warranty terms and conditions see Meritor Warranty Terms and Conditions Publication No 4 84 1 1 100 000 km Brake shoe assemblies Mechanical failure only 1 yr 100 000 km Assister Spring 1 yr 100 000 km Retaining spring 2 yr 200 000 km Anchor pin assembly 1 y
7. SPINDLE END THREAD Any minor damage can be repaired using a 3 48 UNS 2a die nut and holder Meritor part numbers 21226885 and 21224940 Apply a thin even coating of Optimol Optimoly White Paste T available from Meritor Aftermarket Distributors to the bearing journal and abutment shoulder Fig 8 This will reduce spindle wear and assist future removal of the hub assembly FIG 6 3 12 REFIT OUTER BEARING AND RETAINING WASHER Refit the outer bearing cone Fit the retaining washer into the hub ensuring the adjustment indicator markings are facing outwards and fit the retaining clip to hold the bearing cone in place ready for re assembling the hub to axle spindle Fig 7 Refer to Section 3 for refitting procedure FIG 8 TA Hub Re Fitment Procedure RE MOUNT HUB ASSEMBLY If the hub is still assembled to the road wheel and brake drum use a 3 13 CLEAN SPINDLE BEARING JOURNAL wheel dolly to align the hub assembly with the axle spindle adjusting Prior to re assembling the hub onto the spindle check the spindle for the height until the brake drum fits over the brake linings damage and remove any fretting or rust on bearing journals using If the hub and drum assembly is to be replaced separately from the medium grade emery cloth strip Also ensure the inner bearing road wheel ensure it is squarely aligned to the axle spindle during abutment shoulder is clean and free from damage refitting Clean the oil seal journal
8. and eliminate the tack welds the welding procedure recommended in the Meritor suspension manual is followed d more than one weld run is required make the following run with a different start finish point and before the previous run has cooled down Descale between runs e oil rust and thick deposits of paint are removed from the surfaces to be joined f the welding consumables meet the relevant British Standards and are used as recommended by the manufacturer g atthe end of fillet welds the weld is backed up to fill the crater The following precautions will prevent damage to the axle and suspension during welding and improve service life a prevent weld spatter from falling on the axle and road springs b ensure the earth connection is made to the axle beam preventing the passage of current through the wheel bearings do not test the on the axle beam or springs e remove scale and slag from fillet welds before painting to prevent corrosion DO NOT weld in this area top and bottom Sepis 1104 eee siu PI M WELD DETAILS GENERAL REQUIREMENTS FOR AXLE BEAM TA amp Service TA Axle Maintenance Schedule SERVICE ROUTINE TA TAC Disc amp Drum CHECK BRAKE ADJUSTMENT AND CHECK WHEEL NUT TORQUES TA TAC Drum LUBRICATE CAMSHAFT BEARINGS TA TAC Drum BRAKE INSPECTION amp SERVICE an ArvinMeritor brand FREQUENCY
9. brake pads removed check the integrity of the guide pin and tappet dust covers They should be secure and free from any signs of damage Check that the caliper housing assembly slides freely on the guide pins WARNING Take care not to trap fingers whilst checking the sliding action of the brake Examine the brake disc for corrosion grooving and signs of deep crazing If there is any doubt in the serviceability of any component refer to the vehicle manufacturer for corrective action Whilst wearing suitable eye protection remove all traces of scale dirt etc from the pad apertures abutment faces and around the edge of the disc particularly that encroaching onto the braking area A scraper or old screwdriver supported on the caliper body whilst the disc is rotated will removed most of the corrosion Finish off if necessary with emery cloth Remove all traces of scale dirt etc from the pad apertures and abutment faces that may restrict the movement of the pads and therefore prevent efficient adjustment of the brake FIG 10 Fitting New Pads With the brake fully de adjusted it may be necessary to lift the tappet 7 Position the new pads springs correctly on the pad backing plates boots to release any trapped air which may be inflating the dust cover Fig 10 8 De adjust the brake until with the housing pulled across there is a Fig sufficient aperture to fit the new outboard pad Fit the new 10 Fit the new inboard pad outbo
10. fitment of its axles to suspensions of unknown characteristics an ArvinMeritor brand Stresses and welding During use the axle beam is subjected to a wide variety of forces These are caused by the payload bumps in the road surface cornering and braking Because these forces are constantly varying the stresses in the axle beam also vary causing fatigue The top and bottom of the beam generally experience the greatest stresses and hence the most fatigue whilst the section of beam around the horizontal centre line sees the least stress and fatigue Welds in the high stress areas will adversely affect the fatigue strength for this reason do not weld in the area 95mm wide top and bottom of the beam or 50 either side of the vertical centre line as shown in the diagram below Weld tacks or weld spatter are not allowed in this area The beam material is controlled to ensure that pre heating is normally not necessary when welding as per BS5135 The direction of welding should be as near the horizontal as possible and welding around the corners of brackets or spring seats should be avoided Separate drawings exist on request from the Meritor Technical Sales Department detailing seat welding procedures for both air and mechanical Meritor suspensions The effects of welding will be minimised if a all tack welds are at least 25mm long b the number of tack welds is kept to a minimum If possible clamp the bracket tightly to the beam
11. locate the drum onto the hub spigot and rotate to align the bolt holes FIG 1 CAUTION Ensure all mating surfaces are clean dry and free from burrs prior to assembly If reusing the original hub care should be taken to align the serrations on the bolt with the channels previous cut in the hub Using the wheelbolt driving tool Meritor part number 21211274 drive each bolt until the head is fully seated against the drum flange Fig 2 Assemble the ten studs in a diagonal sequence CAUTION Ensure that there is NO gap between the hub flange and wheel bolt head after assembly an ArvinMeritor brand FIG 2 5 2 FITTING AN ABS POLE WHEEL With the hub and drum removed from the axle place it oil seal end upwards on a clean flat surface and cover the bore with a clean cloth to protect the bearings and grease from contamination Check that the pole wheel mounting spigot on the hub is clean and free from rust using medium emery paper to clean it up if necessary Ensure no emery dust or other debris contaminates the bearings or grease The pole wheel can be fitted hot or cold using the oil seal driving tool Meritor Part No 21224749 If fitting hot heat the pole wheel evenly to a maximum of 150 C using a hot plate or induction heater and place onto the hub spigot ensuring it fully seats If fitting cold use the oil seal driving tool to drive the pole wheel onto the hub spigot ensuring it bottoms out against the mountin
12. material reaches a thickness of 3mm 2 Anti rattle springs The pads have anti rattle springs attached Inspect for bent cracked or broken springs If springs are damaged replace with new Refer to Pad Removal and Replacement 3 Seals Caliper should be replaced if any of the seals are found to be cracked torn or damaged in any way 4 Caliper slides freely on slide pins Clearance between the rotor and the pad should be transferred from the inboard rotor surface to the outboard rotor surface by sliding the caliper back and forth 5 Disc Rotor Inspect the rotor for cracks deep scores or other damage Replace the rotor when necessary TA amp Service INSPECTION AND TROUBLE SHOOTING CONDITION 1 Brake Drag POSSIBLE CAUSES Incorrect pad to rotor clearance Improper initial adjustment Vehicle air system malfunction CHECK FOR Total pad gap to be 0 5 to 1 5 mm in service operation an ArvinMeritor brand CORRECTIONS Replace caliper saddle assembly Readjust per Section 2 2 Repair or replace parts as required 2 Short outboard inboard pad life Caliper seized or sticking on slide pins Damaged slide pin seals Caliper should move back and forth by hand with pads removed Replace caliper saddle assembly 3 Short pad life Refer to 2 and 3 Refer to 2 and 3 Refer to 2 and 3 Abusive use of brake system Driver technique Train drivers Rotor sur
13. removing brake dust or corrosion from adjacent areas TA amp TAC Service Assemble the hub bearing guide sleeve Meritor part number 21226490 over the thread of the spindle ensuring the split in the clip is orientated equally over the spindle keyway Fig 8a Before fitting the hub ensure the hub bearing bore is in line with the guide sleeve and the key on the retaining washer is aligned with the keyway on the spindle end Push the hub assembly over the sleeve and fully onto the spindle bearing journal taking care not to damage the oil seal Remove the guide sleeve from the spindle thread 3 15 REFIT HUB LOCKNUT Fit the hub locknut Fig 9 and tighten using hub nut spanner from the TA Service Kit Meritor part number 21226884 until the nut is fully engaged on the spindle thread FIG 9 3 16 HUB LOCKNUT SETTING PROCEDURE 3 16 1 Torque the nut to 100 Nm WHILST ROTATING THE HUB The hub MUST be rotated 5 10 revolutions whilst the end nut torque is continuously applied an ArvinMeritor brand 3 16 2 Back off the nut one flat of the socket i e 1 8 turn anti clockwise 3 16 3 Remove the hub nut spanner Rotate the nut in a CLOCKWISE direction i e in the tightening sense until the corners of the nut align with the NEXT nearest mark on the face of the retaining washer Fig 10 Should the corners of the nut already line up EXACTLY with an index mark do not further rotate the nut FIG 10
14. spring 1 2 4 Lift off top shoe FIG 2 1 3 INSPECTION 1 3 1 Inspect brake anchor pins and bushes for wear Check and replace 0 rings as required 1 3 2 Inspect cam rollers If removed from the brake shoe the roller retained clip must be replaced an ArvinMeritor brand 1 3 3 Inspect brake shoes for wear at anchor pin and cam roller location points 1 3 4 Prior to re assembly the following parts should be lightly coated with Meritor Brake Lubricant i of Camshaft Bushes ii Cam Roller trunion bearing surfaces and D slots in brake shoe iii Brake Anchor Pin bearing surfaces and D slots in Brake Shoe 1 3 5 Ensure greasing is carried out to the four grease nipples on each axle Use Meritor Brake Lubricant 1 3 6 Check brake drums for cracks scoring or other damage 1 3 7 Replace all worn parts with genuine Meritor parts The use of non Original Meritor parts will nullify all warranty and may substantially reduce service life 1 4 REFITTING BRAKE SHOES 1 4 1 Fit return spring roll pin if not already fitted and cam rollers lubricate D holes with Meritor Brake Lubricant Fig 3 1 4 2 Fit anchor pins applying Meritor Brake Lubricant inside the anchor pin bushes and between the 0 ring seals Fig 4 FIG 3 FIG 4 TA amp TAC Service Note f anchor pin bushes worn or damaged they should be 1 4 5 Fit both retaining springs to top shoe and
15. 4 This condition indicates that the rotor has been subjected to extremely high temperatures that have caused a structural change in the rotor material and have caused the rotor to be more susceptible to cracking Rotors may be turned to remove hard raised areas See skimming If resurfacing does not remove the spots the rotor must be replaced Max length 75 of A FIG 14 Rotor Run Out Use a Dial test Indicator DTI to check the run out both axially and radially as in Fig 15 Axial Run out should not exceed 0 3mm over the rotor braking surface when the rotor is turned on properly adjusted wheel bearings Excessive run out may be due to incorrect mounting of the hub fastener torque s or mal adjusted bearings Radial Run out should not exceed 0 8mm total indicator reading an ArvinMeritor brand Skimming Resurfacing the rotor is permissible to a minimum thickness of 42mm Rotor must be replaced at 40mm thickness Surface finish after Thickness machining should Rotor thickness must not vary by more than be 5 microns 0 13mm across any two points of the rotor maximum faces A 1 A FIG 15 Additionally the condition of the cast ABS teeth should be checked to ensure that there are no broken or damaged teeth or that there is no excessive corrosion If in doubt a full ABS functionality check should be carried out TA amp TAC Service
16. Before entering service After 150 km After 1500 km Every months e After any wheel fixing removal e After any brake service e Recommended maximum at 3 monthly intervals Note If other than Meritor Brake Lubricant Total Fina is used or where vehicles are in contact with severe abrasives a max of 6 week interval necessary Linings should be inspected every 6 weeks or 25 000 kms and must be replaced as an axle set if worn down to the wear indicator 8mm Full stripdown should be prior to 1st annual test or at 1st reline whichever is soonest THEN Annually or at every subsequent brake reline Whichever is most frequent TA TAC Disc BRAKE INSPECTION amp SERVICE Pads caliper and rotor should be inspected every 50 000 kms or 3 months Pads should be replaced as an axle set if worn to a lining thickness approaching 3mm At intervals of 100 000 kms or every 6 months preferably when changing pads the opportunity should be taken to remove any accumulations of wear debris and rust from the edge of the rotor and from the pad location points in the caliper Check also condition and location of sealing boots The above service intervals are recommended maximums under normal operating conditions Unusual ambient temperatures or adverse operating conditions e g dusty atmospheres or severe gradients will require more frequent service intervals It is the responsibility of the vehicle operator to establish th
17. PET NUT TAPPET SCREW PLAIN BUSH INBOARD PAD A Cf WT 2 222 SS SS 2 HEAD HALF ROLLER RETURN SPRING GUIDE SLEEVE FRICTION SPRING 28 NS 20 ISS bots eb e OH WO IS WS 7 22222 KKK lt lt 27 SAS Y em T ME OVAL BUSH VISUAL WEAR INDICTOR z SS SS OUTBOARD PAD FIG 2 TA amp Service The air actuated disc brake has been designed to incorporate a direct mounted air chamber Fig 3 The basic operation of the caliper is simple but it is important that the features of the load insensitive automatic adjuster are clearly understood It is essential that the correct service procedures are observed to ensure that the caliper gives satisfactory service throughout its working life FIG 3 How it works The air chamber actuator is attached to the caliper body and operates directly onto the internal operating shaft assembly thus removing the necessity for the conventional external lever and linkage arrangement Sealing between actuator and caliper is achieved by seals located in the caliper coverplate and actuator assembly The carrier secured to the vehicle straddles the disc and supports the brake pads The body assembly slides on two fully sealed guide pins bolted to the bra
18. Reserved Publication 4 92 1B ArvinMeritor Inc World Headquarters 2135 West Maple Road Troy Michigan 48084 U S A Telephone 1 248 435 1000 ArvinMeritor Commercial Vehicle Aftermarket AG Neugutstrasse 89 8600 D bendorf Switzerland Telephone 41 0 1 824 8200 Fax 41 0 1 824 8264 ArvinMeritor Commercial Vehicle Systems Postbus 255 5700AG Helmond Churchilllaan 204A 5705BK Helmond Holland Telephone 31 0 492 535805 Fax 31 0 492 547175 ArvinMeritor South Africa Commercial Vehicle Systems Telephone 27 0 83 602 1603 Descriptions and specifications were in effect at the time of publication and are subject to change without notice or liability Meritor reserve the right to make design improvements change or discontinue parts at any time ArvinMeritor
19. able to a suitable multimeter Rotate the hub by hand at a constant rate of approximately 30 rpm and note the maximum and minimum readings The minimum permissible voltage reading is 400 millivolts and the ratio of maximum minimum should not exceed 2 If either values are not obtained check the installed air gap between the sensor and pole wheel does not exceed 0 7 millimeters and the pole wheel run out does not exceed 0 2 millimeters If the installation is still not correct contact the supplier of the ABS equipment for further advice an ArvinMeritor brand 5 4 FITTING OF HUBODOMETER The TA axle may be fitted with an hubodometer by using a special hub cap It is not possible to fit an hubodometer to a standard hub cap and attempting to do so will affect the hub sealing and may damage the spindle For hubodometer types up to 85mm outside diameter use hub cap Meritor Part No 21226118 It is advisable to assemble the hubodometer to the hub cap prior to fitting the hub cap to the axle Place the hub cap on a clean flat surface Fit the nut to a suitable open ended spanner and using a small amount of grease place the washer onto the nut Using the spanner position the nut and washer under the mounting hole in the cross bar of the hub cap Lower the hubodometer through the hole to engage the thread Rotate the hubodometer to screw the nut along the mounting stud until hand tight Finally tighten the nut with the spanner in the normal way F
20. ameter exceeding 423 mm be re assembled with new brakes shoes 1 14 BRAKE DRUM REPLACEMENT To replace the brake drum the hub and drum assembly must be removed from the axle with the wheels removed It is necessary to remove all the wheel bolts using the procedures described in Section 5 1 TA amp TAC Service TA amp TAC Service Section 2 TA TAC Disc Brake Service an ArvinMeritor brand 83 09 1510 134491 Qv3H 134491 U3NIVI3H 5 1800 313115 30109 1108 31914 31114 8 Service 2 1 INTRODUCTION SECTION 2 Vd 313375 30119 sna 1VA0 SNISNOH dvd 08708100 H TVAO 2 1108 PL j m a 8 19 31VIQ3IAH3INI YOLVIIONI TWNSIA 3 Sus 1344 1 3 c amp 7 uaisnrav 08 39 HOSNIS HSN NIV Td 1108 Nid 301N9 LSNA ualrsnrav u3Tiod TWAS 15 NOILVLOY ILNV dV9 Nid FIG 1 91445 QUVOaNI 3AILVNY3LTIV J4VHS 40 1 5 9 31V 1d83A09 437104 31033N WAS YOLVNLOV 1108 31 1483 09 OPERATING SHAFT NEEDLE ROLLER BEARING SLIDE BLOCK ANTI ROTATION PLATE ADJUSTER ASSEMBLY INTERMEDIATE MULTI PLATES CLUTCH PLATES ADJUSTER GEAR GUIDE SLEEVE TAP
21. an ArvinMeritor brand Meritor Axle amp Brake Service Manual TA and Series Axles including Disc and Drum Brake variants ArvinMeritor INDEX Section Description QUICK REFERENCE WARRANTY CHART THE AXLE IDENTIFICATION PLATE Identifying the Axle Type Identifying the Serial Number INTRODUCTION TO THE AXLE RANGE TA TAC MAINTENANCE SCHEDULE TECHNICAL DATA TABLES TA TAC DRUM BRAKE SERVICE TA TAC DISC BRAKE SERVICE TA TAC HUB SERVICE FOR DRUM BRAKES TA TAC HUB SERVICE FOR DISC BRAKES ADDITIONAL PROCEDURES ArvinMeritor brand Page 11 17 27 4 45 7 an ArvinMeritor brand Quick Warranty Reference Chart TA Cartridge and TA Hubs Any component not referred to below is covered by a 1 yr 100 000 km warranty for mechanical failure only Labour costs can only be claimed at an agreed rate with Meritor Service Department prior to work commencing For full warranty terms and conditions see Meritor Warranty Terms and Conditions Publication No 4 84 1 TA CARTRIDGE 100 000 km 1 100 000 km Oil Seal Hub cap amp screws 4 Mechanical failure only 1 yr 100 000 km Stake Washer assembly Mechanical failure only 1 100 000 km Hub cap gasket Mechanical failure only 7 yr 1 000 000 km TA Cartridge Hub assembly Disc brake hub assembly shown 1 yr 100 000 km Hub cap amp screws 5 yr 500 000 km Axle end nut 1 100 000 km
22. an area Identify the bearing cone clearly to ensure that it is refitted to its original position in the hub FIG 5 3 6 CHECK GREASE CONDITION If the grease within the bearing is clean and does not appear burnt there should be no necessity to totally clean down the assembly Check the hub cavity for any grease contamination caused during hub removal from the spindle Any contamination must be removed or if this is excessive a complete hub clean down must be carried out Refer to Section 3 7 fy an ArvinMeritor brand 3 7 CLEANING OF HUB Wipe clean the hub cavity removing all the old grease and any contamination 3 8 INSPECT BEARINGS Check both bearings cones and raceways for Cage damage Corrosion Roller and raceway damage or pitting Metallic debris or flaking Bearing cup security Ensure both bearing cups are well secured in the hub by checking they are fully seated within the hub bore and with a good grip of the cups try to rotate them If any movement of the cups is detected then the hub will have to be replaced Do not attempt to fit new bearings into a hub with worn bores If any of the above defects are evident the complete bearing cup and cone MUST be replaced 3 8 1 Replace Hub It is advisable to replace with a complete new hub and bearing assembly which is available from Meritor Aftermarket Distributors 3 8 2 Individual Bearing Replacement Procedure Drift out the bearing cup from the hub ensur
23. ard pad Fig 9 11 To adjust the pads locate a 10 mm socket spanner on the adjuster stem and turn it in the appropriate direction refer to the Manual Adjustment section 2 2 for details Continue to adjust the brake until the pads contact the disc NOTE Do not exceed 40 Nm torque on the adjuster stem 12 De adjust the brake by turning the adjuster stem back 1 4 of a revolution Ensure the brake disc is free to spin Ensure the sealing area on the cover plate is clean Always replace the adjuster stem cover Fig 11 FIG 9 9 Push the housing back towards the disc until the new pad contacts the disc face Continue to de adjust the brake until the aperture gap between the tappet heads and the disc face is large enough to accept the new inboard pad NOTE This dimension should be approximately 29mm 31mm Do not exceed the 40Nm maximum torque on the adjuster shaft FIG 11 TA amp TAC Service FIG 12 13 Refit the pad retaining plate and torque the fixing bolt to 33 40Nm 14 In a new pad condition the end of the indicator stem will extend past the edge of the housing casting Fig 12 As the pads wear the length of indicator visible past the edge of the casting will reduce The indicator is incremented with each increment equating to a level of pad wear Fig 13 15 Wind in the spring brake retraction bolt where applicable Refit the road wheels remove the axle strands and lower the vehicle to
24. ate direction To indicate the direction required to adjust or de adjust the brake and symbols are cast onto the cover plate on the front face of the adjuster turret Fig 5 FIG 5 an ArvinMeritor brand NOTE Turn the adjuster stem in the direction of the sign to adjust the brake Turn the adjuster stem in the direction of the sign to de adjust the brake From a fully worn pad condition it will require approx 9 full revolutions of te adjuster stem to fully de adjust the brake IMPORTANT Always de adjust adjust the brake carefully by hand with a suitable Spanner Never exceed a maximum torque of 40 Nm in either direction and NEVER use power tools air or electric to de adjust or adjust the brake 2 3 BRAKE INSPECTION AND TROUBLE SHOOTING WARNING Do not work under a vehicle supported only by jacks Jacks can slip or fall over and cause serious personal injury Support the vehicle with safety stands block the wheels to prevent the vehicle from moving Inspection Schedules Inspect the brake according to one of the following schedules Use the schedule that gives the most frequent inspection The schedule for chassis lubrication used by your fleet The schedule for chassis lubrication recommended by the manufacturer of the chassis At least every 3 months e During tyre replacement Inspection should include the following 1 Pad wear The pads must be replaced at or before the amount of pad
25. bore of the inner bearing cone and drive the seal fully home ensuring the seal remains square to the hub at all times Fig 19 The seal will bottom out on the inner hub shoulder and the outer face will remain proud of the hub when fully installed FIG 19 Hub Re fitment Procedure 3 25 CLEAN SPINDLE BEARING JOURNAL Prior to re assembling the hub onto the spindle check the spindle for damage and remove any fretting or rust on bearing journals using medium grade cloth strip Also ensure the inner bearing abutment shoulder is clean and free from damage Clean the oil seal journal removing brake dust or corrosion from adjacent areas 3 26 CHECK SPINDLE END THREAD Any minor damage can be repaired using a 3 480 UNS die nut and holder Meritor part numbers 21226885 and 21224940 Apply a thin even coating of Optimol Optimoly White Paste available from Meritor Aftermarket Distributors to the bearing journal and bearing abutment shoulder Fig 20 This will reduce spindle wear and assist future removal of the hub assembly an ArvinMeritor brand FIG 20 3 27 RE MOUNT HUB ASSEMBLY If the axle is fitted with ABS check the condition of the sensor and pull it fully forward in its mounting block or bracket dependant on whether axle is fitted with drum or disc brakes If the hub and drum is still assembled to the road wheel use a wheel dolly to align the hub assembly with the axle spindle adju
26. cessity for the conventional external lever and linkage arrangement Sealing between actuator and caliper is achieved by seals located in the caliper coverplate and actuator assembly The carrier secured to the vehicle straddles the disc and supports the brake pads The body assembly slides on two fully sealed guide pins bolted to the brake carrier As the pads wear adjustment takes place automatically and independently of load Axle Installation The following notes and recommendations are offered as a guide to the trailer manufacturer and service engineer They are based on experience gained from both the manufacture and servicing of single and multiple axle installations Limitations of use The following limitations apply to the TA axle series fitted with either 22 5 super single or twin tyres and used in semi trailer or drawbar arrangements For normal on highway and RO RO use the axle beam is supplied in a range of three beam wall thickness dependant axle loading For full details of capacity and Flexair suspension installation options please consult Meritor Technical Sales Department In cases where suspensions of non Meritor manufacture are used the trailer builder or suspension manufacturer must satisfy themselves as to the suitability and compatibility of the axle and suspension particularly from an installation and durability standpoint Meritor will be pleased to assist in assessing such compatibility but cannot warrant the
27. crews using 5mm A F Allen key Fig 2 The hub locknut should be removed using hub nut spanner from the Meritor TA Service Kit Meritor part number 21226884 It is recommended that the retaining clip and retaining washer are left in the hub until the hub assembly has been removed from the spindle 3 3 REMOVAL OF HUB Remove the hub assembly from the axle using a hub puller Meritor part number 21224863 The five M8 hub cap screws may be used to secure the hub puller to the hub face Fig 3 If the hub is to be removed whilst still assembled to the road wheel and brake drum use a wheel dolly to support the weight of the assembly an ArvinMeritor brand FIG 2 FIG 3 3 4 REMOVAL OF OIL SEAL AND INNER BEARING CONE The oil seal should be removed from the hub using an oil seal removal tool Meritor part number 21218565 and suitable lever Fig 4 THE SEAL MUST BE DISCARDED NEVER RE USE AN OIL SEAL AFTER THE HUB HAS BEEN DISMOUNTED FROM THE AXLE SPINDLE Remove the inner bearing cone and place it in a clean area Identify the bearing cone clearly to ensure that it is refitted to its original position in the hub amp Service FIG 4 3 5 REMOVAL OF RETAINING WASHER AND OUTER BEARING CONE The retaining clip can now be removed from the outer side of the hub with a pair of pliers or suitable screw driver Remove the retaining washer Fig 5 Remove the outer bearing cone and place it in a cle
28. ensure the park brake is fully released Wind off the spring brake retraction bolt where appropriate Jack up the axle and fit suitable axle stands securely Remove the road wheels and it is advisable to exhaust all air from the system Remove any dirt from the caliper assembly Ensure the rubber dust covers fitted to the tappet heads and guide sleeves are not damaged an ArvinMeritor brand 50 Wear 75 Wear 25 Wear Maximum Wear FIG 7 WARNING Never use an air line to blow dust from the brake disc area If inhaled any form of dust can at best be an irritant at worst dangerous Wherever possible remove dry brake dust with a vacuum brush Alternatively wipe the areas with a damp cloth never try to accelerate drying time by using an air line 3 Remove the pad retaining plate bolt and pad retaining plate from the caliper 4 It may be necessary to de adjust the brake initially to remove the worn brake pads Locate a suitable 10 mm socket spanner on the adjuster stem and rotate the spanner in the appropriate direction refer to the Manual Adjust section 2 2 for details IMPORTANT Always de adjust adjust the brake carefully by hand with a suitable spanner Never exceed a maximum torque of 40 Nm in either direction and NEVER use power tools air or electric to de adjust or adjust the brake 5 Remove the brake pads Fig 8 FIG 8 fy TA amp TAC Service ze Cleaning and Inspection 6 With the
29. er away from the clevis sides Remove the circlip retaining the slack adjuster and slide the assembly off the camshaft spline remove all packing washers and boots around the slack adjuster Release the camshaft from the head end retaining clip by striking the end of the shaft with a copper mallet Fig 10 Make sure the cam head rubber boot retaining clip is removed before attempting to remove the shaft The camshaft can now be removed FIG 10 1 8 SPHERICAL BEARING INSPECTION AND REMOVAL Inspect both splierical bearing for damage and wear Both bushings can be removed using a 13mm spanner to remove the four M10 screws securing the iner and outer bushings See Fig 11 an ArvinMeritor brand FIG 11 1 9 REPLACEMENT OF CAMSHAFTS AND CAMSHAFT BEARINGS Clean the full length of the camshaft prior to assembly Ensure the faces of the anchor bracket and camshaft bracket are clean Slide the under head rubber boot onto the camshaft Pass the camshaft through the brake anchor bracket from the outboard side slide the cam head bearing inner rubber boots cover plate and spline end spherical bearing onto the camshaft In the case of 420 x 180 drum brake only Fasten both camshaft bearings in place using the M10 screws DO NOT FULLY TIGHTEN THE BEARING SECURING SCREWS UNTIL THE BRAKE SHOES ARE REASSEMBLED A hard tap on the cam head with a copper mallet will be required to locate the spring clip into the camsha
30. ese intervals Disc amp Drum HUB AND BEARING INSPECTION INCLUDING OIL SEAL REPLACEMENT Whenever hubs are removed from axle Annually after 1st major hub overhaul TA Disc amp Drum MAJOR HUB SERVICE If a problem is found during inspection Prior to 2nd annual test or after 300 000 km whichever occurs first TAC Disc amp Drum HUB AND BEARING INSPECTION INCLUDING OIL SEAL REPLACEMENT The TAC hub assembly is maintenance free However a visual inspection should be carried out and the auxiliary oil seal replaced whenever the hub is removed from the axle Note The TAC hub is not a serviceable item Any problems should be reported to Meritor Service Department amp Service Technical Data Tables TABLE 1 FASTENER TORQUE VALUES DRUM DISC BRAKE Hub cap screws 11 15 Nm TA Axle lock nut Refer to setting procedure Section 3 16 Button head screws axle lock nut 15 20 Nm TAC Axle lock nut 700 750 Nm Wheel nuts 680 750 Nm TABLE 2 FASTENER TORQUE VALUES DRUM BRAKE ONLY Dust cover bolts Q amp Z brakes 50 60 Nm Dust cover nuts Q brake only 11 15 Nm Spherical bearing bolts spline end 50 60 Nm Cam head bearing bolts 50 60 Nm ABS sensor block fixing bolt 30 50 Nm TABLE 3 FASTENER TORQUE VALUES DISC BRAKE ONLY Rotor fixing bolts 230 270 Nm Caliper retaining bolts Torque amp Angle Procedure Initial torque 300 Nm PLUS ADDITIONAL 45 bolt rota
31. face Cracks or heavy heat checking Refer to Section 1 8 Refer to Section 2 5 for rotor inspection Non genuine pads Vehicle overload See GAWR limitations on vehicle plate Fit Meritor pads Observe vehicle manufacturers load recommendations Companion brakes not working properly Inspect companion vehicles brakes and air systems Adjust or repair as required 4 Brake smoking High brake temperature Refer to 2 3 and 4 Refer to 2 3 and 4 Contamination of pads Grease oil etc on pads Incorrect pad to rotor clearance Check running clearance Inspect hub seal Replace as required Clean rotor and caliper assembly Replace pads per Section 2 4 5 Poor stopping power Long stopping distances Poor driver feel High brake pressures Lack of normal response Vehicle pulls to one side Vehicle air systems malfunction Proper air pressure at the chamber inlet Have the air system evaluated by a qualified brake system specialist Brakes out of adjustment Check running clearance Replace caliper saddle assembly Refer to Section 2 6 Vehicle overload See GAWR limitations on vehicle 1 0 plate Observe vehicle manufacturer s load recommendations Contamination on pads Grease oil etc on pads Inspect hub seal and replace pads per Section 2 4 Companion brakes not working properly Inspect companion vehicle brakes and air system
32. ft groove With the camshaft in position refit the spline end rubber boot slack adjuster packing washers and circlip 1 10 REFIT DUST COVERS Dust cover replacement is a reversal of the removal procedure See section 1 6 fy TA amp TAG Service 1 11 GREASE CAMSHAFT BEARINGS Grease the camshaft bearings using a grease gun Fig 12 Always use Meritor Brake Lubricant FIG 13A FIG 12 1 12 LUBRICATE BRAKE CHAMBER CLEVIS PIN ASSEMBLY Lubricate the clevis pin assembly from both sides with oil and make sure the brake can be operated easily by pulling the slack adjuster by hand 1 13 INSPECT BRAKE DRUM Clean excess brake dust from the brake drum and inspect the drum braking surface for corrosion excessive wear or other damage Remove light corrosion by using coarse emery cloth at an angle of 45 FIG 13B degrees in one direction and then 45 degrees in the other direction to produce a cross hatch effect DO NOT USE ANY FORM OF POWER TOOL If the drum surface shows signs of light heat crazing it usually can be reused Fig 13A but if the heat crazing is severe the drum should be replaced 13B Should the drum life be extended by turn out machining the recommended machining limit should be 423 mm diameter so that during the projected wear out life of the shoes the final drum diameter must not excess 424 0 mm Similarly excessively worn drums should be inspected and on no account should drums of di
33. g shoulder Fig 3 FIG 3 TA amp TAC Service 5 3 FITTING AN ABS SENSOR 5 3 1 Sensor Block Assembly Apply Meritor Brake Lubricant grease to bush Assemble the spring bush into the sensor mounting block Fig 4 Push the sensor fully into the mounting block assembly When the hub is refitted the pole wheel will push the sensor back thus attaining the correct clearance FIG 4 5 3 2 Fix Sensor Block Assembly to Axle Beam All axle beams are provided with a sensor block bolt fixing hole and location step The hole is located on the spindle end behind the oil seal journal and is orientated between the two anchor pin bushes Position the mounting block assembly so that the two small feet on the front edge of the block locate over the step on the spindle just forward of the bolt hole Line up the bolt hole in the block with the hole in the beam and engage the M10 thread forming fixing bolt ALWAYS USE THE CORRECT BOLT Refer to Meritor Parts List Tighten the fixing bolt evenly to the torque specified in table 1 Ensure the block is correctly seated and fully clamped The sensor may be rotated in the mounting block to allow the cable to pass either side of the anchor bracket Pass the sensor cable through the dust cover using the uppermost hole and fit the strain relief grommet Ensure the lower cable exit hole in the dust cover is fitted with a blanking plug 5 3 3 Checking Sensor Output Connect the output c
34. he adjuster clutch to slip As a result the multi plate clutch becomes a solid link thereby rotating the adjuster gear which in turn rotates the adjacent tappet gear and via the intermediate gear assembly the second tappet gear extending the length of the tappet screw to reduce the pad to disc clearance Once the pads contact the disc any further rotation of the operating shaft will increase the clamp load between pad and disc and cause the multi plate clutch to slip and the adjuster stops operating preventing over adjustment When the brakes are released the actuating mechanism returns removing the clamp load from the pads At the same time the adjuster returns to its original position providing the designed pad to disc running clearance Any further reverse movement of the adjuster assembly results in the sprag clutch slipping until the op shaft reaches it s rest position The friction spring return plate and tappet nuts prevents de adjustment therefore leaving the tappet arrangement in its newly adjusted position TA amp TAC Service 2 2 MANUAL ADJUSTMENT The brake adjuster assembly is provided with a manual override facility which allows the brake to be de adjusted and adjusted manually when fitting new pads To manually adjust or de adust the brake carefully remove the adjuster stem cover locate a suitable 10 mm socket spanner on the adjuster stem Fig 4 and rotate the adjuster stem with the socket spanner in the appropri
35. ified in table 1 Continue to rotate the hub whilst the final torque is applied Fig 23 Fit the retaining washer assembly Fig 21 by aligning the retaining washer key with the spindle keyway Ensure the washer assembly is fitted the correct way round with the dish of the stake washer facing outwards Fig 22 FIG 23 FIG 21 TA amp TAC Service 3 30 STAKING THE WASHER AXLE END NUT en Using the staking tool from the Meritor TAC Service Kit Meritor part No 21226453 stake previously unused section of the outer flange of the stake washer into ONE of the slots on the face of the nut flange Fig 24 The washer material should be split along the edge of the flat end of the slot in the nut and formed over progressively into the remaining length of the slot so as to resist the unwinding of the nut in the event that torque is lost Fig 25 FIG 26 FIG 24 FIG 27 Fig 26 and Fig 27 show incorrect locking procedure It is possible to complete the staking operation by using a piece of 10mm x 10mm square bar by placing the end of the bar on the staking washer flange at a shallow angle Carefully align it so that the one side of the bar is in line with the flat end of the slot in the nut flange Do not use a sharp bladed tool such as a chisel or screw driver FIG 25 TA amp TAC Service 3 31 CHECKING THE BEARING SETTING Check for free rotation of the hub assembl
36. ig 5 The hub cap and gasket can now be fitted to the axle as described in Section 4 7 FIG 5 TA amp TAC Service 5 5 REMOVAL AND REFITTING OF WHEEL BOLTS With the hub removed from the axle support it by placing blocks under the flange or if the rotor is still attached stand the inboard face of the rotor on a clean flat firm surface Using the wheel bolt removal tool Meritor Part No 21205455 drive out the wheel bolts Fig 6 FIG 6 Wind the new stud into the hub using spacer washers and a wheel nut Ensure the gap under the bolt head does not exceed 0 1mm Fig 7 FIG 7 an ArvinMeritor brand 5 6 FITTING AN ABS SENSOR 5 6 1 Sensor Block Assembly Apply Meritor Brake Lubricant to the bush Assemble the spring bush into the sensor mounting bracket Push the sensor fully into the mounting bracket assembly Fig 8 FIG 8 When the hub is refitted the pole wheel will push the sensor back thus attaining the correct clearance 5 6 2 Fix Sensor Bracket to Axle Beam All disc brake axle beams are provided with two sensor bracket fixing holes on the torque plate Locate the bracket against the outboard side of the torque plate such that the fixing holes line up Assemble the two fixing screws from the inboard side of the torque plate through the holes and into the threaded holes in the sensor mounting bracket as shown in Fig 9 FIG 9 Tighten the two screws evenly to the torque
37. ing that the bearing bore within the hub is not damaged Bearing Cup Refitment ALWAYS USE GENUINE MERITOR BEARINGS STANDARD ISO BEARINGS CANNOT BE USED Insert the bearing cup into the hub and using a bearing cup driver Meritor part number 21218569 drive the cup fully home ensuring the cup sits squarely against the hub shoulder 3 9 REGREASE BEARINGS Thoroughly pack both bearing cones with Meritor Hub Grease Blue Lithium EP2 and refill the bearing cavity Refer to table 5 for correct grease quantities Note Greased bearings should always be placed in a clean area 3 10 REFIT INNER BEARING Refit inner bearing cone into the inner bearing cup pressing fully home to assist location of oil seal driver TA amp TAC Service ze 3 11 FIT NEW OIL SEAL Press a NEW OIL SEAL onto the oil seal driver Meritor part number 21218568 ensuring the OIL SIDE marking on the seal is visible i e faces away from the plate of the driver such that the seal will be installed the correct way round in the hub Locate the nose of the driver into the bore of the inner bearing cone and drive the seal fully home ensuring the seal remains square to the hub at all times Fig 6 The outer face of the seal should be flush with the back face of the hub when fully installed Check the hub cavity grease and top up as necessary with Meritor Hub Grease Blue Lithium EP2 Refer to table 5 for correct grease quantity FIG 7 3 14 CHECK
38. ke carrier As the pads wear adjustment takes place automatically and independently of load NOTE Load Independent means adjustment takes place under very small clamping forces only therefore preventing over adjustment and minimising air consumption Brake Application without automatic adjustment The actuating mechanism is mechanically driven and incorporates an eccentric operating shaft two hardened rollers and a twin tappet arrangement The fully integrated automatic load insensitive adjusting mechanism is situated to the side of the operating shaft tappet arrangement As the operating shaft rotates it also turns the automatic adjuster via the adjuster drive pin which engages with the sliding block incorporated in the adjuster assembly The adjuster gear meshes with the adjacent tappet nut and therefore is able to transmit the rotation to the tappet arrangement An intermediate gear assembly located between the two tappet assemblies ensures any rotation is transmitted equally across both tappets The tappet screws are prevented from rotating by an anti rotation plate an ArvinMeritor brand The sprag clutch arrangement incorporated in the adjuster assembly has a pre set clearance which the initial movement of the op shaft takes up before any rotation of the adjuster gear and therefore tappet assemblies can take place This pre set clearance maintains the correct running clearance of the brake pads nominally 0 7mm
39. nder the mounting hole in the cross bar of the hub cap Lower the hubodometer through the hole to engage the thread Rotate the hubodometer to screw the nut along the mounting stud until hand tight Finally tighten the nut with the spanner in the normal way Fig 5 to a maximum of 27 Nm The hub cap and gasket can now be fitted to the axle as described in Section 3 18 Es an ArvinMeritor brand an ArvinMeritor brand an ArvinMeritor brand Meritor HVS Limited Commercial Vehicle Systems Rackery Lane Wrexham 1112 0 U K Telephone 44 0 1978 852141 Fax 44 0 1978 856173 Meritor HVS Mitry Mory S A Commercial Vehicle Systems 21 du Moulin Vent 9 rue des Fr res Lumi re 77290 Mitry Mory France Telephone 33 0 1 64 27 44 61 Fax 33 0 1 64 27 30 45 Meritor HVS Verona s r l Commercial Vehicle Systems Via Monte Fiorino 23 37057 San Giovanni Lupatoto Verona Italy Telephone 39 045 8750399 Fax 39 045 8750640 8750513 Meritor HVS Barcelona S A Commercial Vehicle Systems Ctra Granollers Sabadell Km 13 3 Poligono Argelagues 08185 Lli de Vall Spain Telephone 34 9 3 843 95 68 Fax 34 9 3 843 83 59 For further information contact Meritor HVS Limited Commercial Vehicle Systems Rackery Lane Llay Wrexham LL12 OPB U K Telephone 44 0 1978 852141 Fax 44 0 1978 856173 www arvinmeritor com Copyright 2001 Meritor Automotive All rights
40. o the hub face Fig 17 If the hub and drum is to be removed whilst still assembled to the road wheel use a wheel dolly to support the weight of the assembly FIG 17 WARNING This seal must not be confused with the inner and outer main bearing seals which are integral to the bearing unit and cannot be serviced Inspect the hub assembly for general signs of damage Check the two bearing oil seals for leakage NOTE A small witness of grease may be in evidence around the seals This is normal and should simply be wiped clean Wipe the inner bore of the bearing unit with clean dry paper to remove any residue of assembly paste Inspect the spring clip between the two halves of the bearing cone for damage NOTE Never attempt to remove The circular spring bearing retaining clip from the hub The bearing assembly from the hub Either of the two oil seals integral to the bearing unit from the bearing The spring clip between the two halves of the inner bearing cone THIS WILL CAUSE IRREPARABLE DAMAGE TO THE HUB ASSEMBLY AND AUTOMATICALLY INVALIDATE ALL HUB WARRANTY TA amp Service 3 24 FIT NEW AUXILIARY OIL SEAL Press a new oil seal onto the oil seal driver Meritor part No 21218568 ensuring the oil side marking on the seal is visible i e faces away from the plate of the driver such that the seal will be installed the correct way round in the hub Locate the nose of the driver into the
41. o the torque value specified in table 1 Fig 13 Care should be taken not to damage any of the sealing lips on the gasket 3 20 UNDO LOCKING STAKE Using a suitable small chisel or screwdriver lever back the flange of the staking washer where it has been staked to one of the slots in the axle end nut Ensure the washer flange is clear of the nut flange Fig 15 FIG 13 FIG 15 amp Service 3 21 REMOVAL OF AXLE END NUT AND RETAINING WASHER ASSEMBLY The axle end nut can now be removed using the end nut socket from the Meritor TAC service kit Meritor part No 21226453 and a suitable Y drive wrench NOTE The torque required to remove the nut will be at least 700Nm Fully remove the axle end nut and lift away the retaining washer assembly Fig 16 fy an ArvinMeritor brand 3 23 HUB AND BEARING INSPECTION The TAC bearing unit is fully sealed and cannot be serviced It is however recommended that for maximum bearing life the auxiliary seal at the back of the hub is replaced whenever the hub is removed from the axle as damage may have occurred during the hub removal process The oil seal should be removed from the hub using an oil seal removal tool Meritor part No 21218565 Fig 18 FIG 16 3 22 REMOVAL OF THE HUB ASSEMBLY Remove the hub assembly from the axle using a hub puller Meritor part No 21224863 The five M8 hub cap screws may be used to secure the hub puller t
42. ountings and abutment faces on both hub and rotor are clean and free from damage Rotate the hub relative to the rotor until the rotor fixing bolt holes are aligned Fit the 10 rotor bolts and washers Tighten bolts progressively in a diagonal sequence until the final torque specified in table 3 is achieved TA amp TAC Service FIG 3 4 8 HUB AND REPLACEMENT Replace the hub and rotor assembly as described in Section 3 of this Manual 4 9 CALIPER AND PAD REPLACEMENT Replace the caliper refit the pads and ensure correct brake adjustment as described in Section 2 of this Manual TA amp TAC Service TA amp TAC Service Section 5 Additional Procedures for Disc amp Drum Brakes TA amp Service SECTION 5 Additional Procedures Drum Brake 5 1 REMOVAL AND REFITTING OF WHEEL BOLTS Meritor wheelsbolts are pressed into the hub and drum assembly and retained by serrations on the bolt shank Damage to wheelbolts is caused by Loose wheel nuts Overtightened wheel nuts Mismatched wheel type and fixings Cross threaded nut and bolt Mismatched nut and bolt types With the hub and drum assembly removed from the axle place the back face of the drum onto a firm flat surface so that the studs are pointing vertically upwards Using the wheel bolt removal tool Meritor part number 21205455 drive out the wheel bolts Fig 1 To replace the wheel bolts invert the hub and
43. r 100 000 km ABS ts Z i9 bcd 2 yr 200 000 km if 77 Cam beari 1 100 000 km Y L am bearing ABS components lt lt S EE 1 2 yr 200 000 km Camshaft 1 100 000 km Return spring 5 500 000 km Axle beam weld assembly Ex works Including Flexair spring seat 3 yr 300 000 km LM 9300 beam non Meritor welded 2 yr 200 000 km Cam roller assembly 1 yr 100 000 km Brake shoe assemblies Mechanical failure only 3 yr 300 000 km 2 3 e 1 yr 100 000 km 2 Dust covers amp screws failure only TA amp TAC Service ze The Identification Plate Every axle leaving the Meritor factory is fitted with an identification plate which contains all the information needed to ensure the correct replacement parts are obtained AXLE TYPE R APPROVAL No P41ABS15STVZO 55 O A999999 H97 0000 Ero CNN NOM CAPACITY 10170KG MAX cuu opa TUR COMB CAPACITY 10170 KG 105 KM H ASSEMBLED IN THE EEC IDENTIFYING THE AXLE TYPE TA series axles are fitted with 10 stud ISO 4107 spigot mount wheel fixings and asbestos free brake pads or linings as standard Other options are as shown below Anti Lock Type Axle series loading Brake Type Table A Steer Axle 5 Table D Table E Hub configuration Wheel configuration Type of wheel bolts Table B Table C Table F Table A Table B Axle Letter Exciter Ring Sui
44. r concept and commonised features aimed at lower cost of ownership It is primarily intended for 22 5 wheel applications where the axle load is 10 5 tonnes or greater but also provides an ideal solution to all heavy duty braking applications Introduction to the TA Cartridge Concept The TA cartridge bearing hub is an innovative part of the TA series building on the success of the LMC fully sealed maintenance free bearing unit which has set the standard for European trailer axles The TA cartridge offers the optimum combination of bearing performance and reduced service times The cartridge bearing is manufactured to extreme levels of accuracy allowing it to be operated in a precisely controlled preloaded condition for optimum life performance Whilst the hub can be left for up to 7 years without removal from the beam the sealed bearing allows for quick and clean routine brake servicing should the hub need to be removed more frequently Introduction to the Meritor D Duco Disc Brake The Meritor D Duco disc brake is a high performance high efficiency brake designed for Trailers Trucks Coaches Buses and other Commercial Vehicles With a proven truck background this brake offers the highest levels of truck and trailer compatibility whilst providing impressive versatility in braking applications The air chamber is attached to the caliper body and operates directly onto the internal operating shaft assembly thus removing the ne
45. specified in table 3 Ensure the bracket is seated squarely on the torque plate and fully clamped into position The sensor may be rotated in the mounting bracket to obtain the desired cable angle amp Service 5 6 3 Checking Sensor Output Connect the output cable to a suitable multimeter Rotate the hub by hand at a constant rate of approximately 30 rpm and note the maximum and minimum readings The minimum permissible voltage reading is 400 millivolts and the ratio of maximum minimum should not exceed 2 If either values are not obtained check the installed air gap between the sensor and pole wheel does not exceed 0 7 millimeters and the pole wheel run out does not exceed 0 2 millimeters If the installation is still not correct contact the supplier of the ABS equipment for further advice 5 7 FITTING OF HUBODOMETER The TA axle may be fitted with an hubodometer by using a special hub cap It is not possible to fit an hubodometer to a standard hub cap and attempting to do so will affect the hub sealing and may damage the spindle For hubodometer types up to 85mm outside diameter use hub cap Meritor Part No 21226118 It is advisable to assemble the hubodometer to the hub cap prior to fitting the hub cap to the axle Place the hub cap on a clean flat surface Fit the nut to a suitable open ended spanner and using a small amount of grease place the washer onto the nut Using the spanner position the nut and washer u
46. sting the height until the brake drum fits over the brake linings If the hub and drum assembly is to be replaced separately from the road wheel ensure it is squarely aligned to the axle spindle during refitting Assemble the hub bearing guide sleeve Meritor part no 21226490 over the thread of the spindle Fig 20a Before fitting the hub ensure the hub bearing bore is in line with the guide sleeve Push the hub assembly over the sleeve and fully onto the spindle bearing journal taking care not to damage the oil seal Remove the guide sleeve from the spindle thread FIG 20a TA amp TAC Service 3 28 REFIT THE RETAINING WASHER ASSEMBLY 3 29 REFIT AXLE END NUT The retaining washer assembly may be re used twice after original Fit the axle end nut to the spindle thread Wind the nut down the factory fitment After the flange of the staking washer has been bent spindle thread using the end nut socket from the Meritor Service over in three positions the retaining washer assembly MUST be Kit Meritor part No 21226453 Continue until the hub is fully located replaced and at the same time continuously rotate the hub 15 20 complete Lightly lubricate the full dished face of the stake washer with revolutions 19 ensure the bearing rollers are seated Optimol Optimoly white paste T or a conventional hub bearing Using a suitable drive torque wrench apply final tightening torque grease to the value spec
47. table Axle Letter Code Type For Code Hub Configuration W 100t Solid Ring Wabco A Standard Bearing Hub Bosch Cartridge Bearing Hub Grau DGX amp MGX100 Table C Table D Axle Letter Axle Series Nominal Highway Tube Wall Code Wheel Configuration Rating Kg Thickness mm Single 200 9300 13 T Twin For maximum and minimum suspension offsets refer to relevant Meritor TA D DUCO Suspension installation layout The axle ratings shown are for normal highway use and any special application Table F must be approved by Meritor Technical Sales Axle Letter Code ISO 4107 Wheel Mounting Type MX M22 x 1 5p wheel studs for single steel wheels Table E Axle Letter Code Brake Type 420 x 180 Drum Brake MXA M22 x 1 5p wheel studs for single alloy wheels 420 x 220 Drum Brake D Duco Disc Brake IDENTIFYING THE SERIAL NUMBER Non Asbestos Brake Lining Build Month Sequential Number R Dun Order Number Build Year amp Service Introduction to the TA Axle Range The Meritor TA range of axles are manufactured to the same high standards expected of all Meritor products The TA Series has been specifically designed to introduce the new 22 5 disc brake whilst bringing the drum brake range up to date for higher capacity axles The TA Series compliments the existing LM axle range in its modula
48. the air chamber Sequentially tighten each nut to an initial torque shown in table 1 This ensures correct engagement of the air chamber seal against the caliper sealing face and prevents permanent distortion of the air chamber canister Tighten the air chamber nuts to the final torque shown in table 1 Fig 20 FIG 20 Ensure the rubber drainage hole sealing bungs are correctly fitted to the air chamber such that when installed on the vehicle at correct suspension ride height the holes closest to the vertically downward position are left open and all other holes are sealed 6 Follow steps 7 15 of pad removal and replacement section 2 4 to refit the pads an ArvinMeritor brand ei TA amp TAC Service Section 3 TA TAC y 0 gx gt o co 2 5 zn Rm TA amp TAC Service SECTION 3 TA Hub and Bearing Inspection The following procedures can be performed either with the road wheel and brake drum assembled to the hub or with the road wheel removed 3 1 DE ADJUST BRAKES Using the manual adjustment nut on the slack adjuster fully de adjust the brake Follow the appropriate procedure for the type of automatic slack adjuster fitted Instructions are available through the Meritor Technical Sales Department 3 2 REMOVAL OF HUB LOCKNUT Remove the five M8 hub cap screws Remove hub cap and gasket Fig 1 FIG 1 Remove the two socket button head s
49. the following additional procedures are required 4 1 SLACKEN ROTOR BOLTS Before lifting the axle it is advisable to slacken the wheel nuts Lift axle enough to get clearance to remove wheel Support axle with safety stands and remove wheel and tyre Warning Do not work under a vehicle supported only by jacks Jacks can slip or fall over and cause serious personal injury Support the vehicle with safety stands and block the wheels ro prevent the vehicle from moving With the park brake applied slacken the 10 rotor fixing bolts Fig 2 an ArvinMeritor brand FIG 2 4 2 RELEASE BRAKES AND REMOVE THE PADS Release trailer brakes and remove pads as described in Section 2 of this Manual 4 3 REMOVE CALIPER Remove the brake caliper as described in Section 2 of this Manual 4 4 HUB REMOVAL PROCEDURE TA or TAC Remove the hub and rotor assembly as described in Section 3 of this Manual 4 5 ROTOR REMOVAL With the inboard face of the disc rotor laying flat remove the 10 rotor bolts and washers Lift the hub clear of the rotor 4 6 HUB SERVICE AND INSPECTION Carry out hub service and inspection procedures as described in Section 3 of this Manual 4 7 ROTOR REPLACEMENT If the existing rotor is to be re used refer to Section 2 of this Manual for inspection details prior to re fitting With the in board face of the disc rotor laying flat assemble the hub to the rotor as shown in Fig 3 ensuring that the spigot m
50. tion or 500 550 Nm full torque Air chamber nuts Tighten evenly to initial toque 80 100 Nm then re tighten to a final toque of 160 180 Nm ABS sensor bracket fixing bolts 20 25 Nm TABLE 4 RECOMMENDED LUBRICANTS Hub Bearings Meritor Hub Grease Blue Lithium EP2 Elf Lithium EP2 Total Multis EP2 Castrol Spheerol EPL2 Shell Calithia EP2T Shell Alvania Grease EP LF 2 Texaco Multifak EP2 Mobil Mobilux EP2 BPLSEP2 Fina Marson EPL2 Silkolene 062 SKF LGEP2 Eurol Universalfett EP2 GB Lithium EP2 Axel Christiernsson Lithac 162 EP Esso Beacon EP2 Brake Components and Camshaft Bearings Meritor Brake Lubricant Total Fina CERAN WRC2 Spindle Bearing Journal Optimol Optimoly White Paste T TABLE 5 HUB amp BEARING GREASE FILL VOLUMES TA Hub Hub Cavity Inner Bearing Outer Bearing TAC Hub Hub is pre packed no maintenance unit TA amp TAC Service ei TA amp TAC Service Section 1 TA TAC e gt i 9 e i co TA amp Service SECTION 1 Drum Brake Service 1 1 DE ADJUST BRAKES De adjust the brakes and remove the hub and drum assembly as described in Section 3 1 2 REMOVE BRAKE SHOES 1 2 1 Using a screwdriver between brake shoe gussets ease out both retainer springs Fig 1 FIG 1 1 2 2 Take hold of bottom shoe pulling it off the anchor pin tilt forward and lift off camshaft head Fig 2 1 2 3 Remove brake return
51. with a screwdriver replaced using Meritor Anchor Pin Bush Removal Tool 21205456 See pull spring down and ease into bottom shoe Fig 5 Fig 8 FIG 5 FIG 8 1 5 CAMSHAFT WEAR INSPECTION With the brake shoes removed as described in the previous section inspect the camshaft and bearings for wear Lever the camshaft up and down to detect free movement Fig 9 at both the cam head bearing and spline end bearing Camshaft movement should not exceed 3mm total at either bush The amount at the lever will depend on the lever length so discretion and judgement is required FIG 6 1 4 4 Attach bottom shoe to spring push down and in towards cam head and onto anchor pin Fig 7 FIG 9 FIG 7 TA amp Service 1 6 DUST COVER REMOVAL 1 5 1 420 x 220 Z Brake Remove the two halves of the dust cover from the anchor bracket by removing the four 10 screws Release the ABS sensor cable strain relief bush and pass the cable through the dust cover 1 5 2 420 x 180 0 Brake Remove the dust cover by releasing the two M10 screws and the two 8 flange nuts Release the ABS sensor cable strain relief bush and pass the cable through the dust cover Release the filler plate by removing the two M10 screws The filler plate can be finally be removed once the camshaft has been removed 1 7 AND BEARING REMOVAL Detach the clevis on the slack adjuster and rotate the lev
52. y It should not be possible to detect any axial bearing clearance 3 32 REFIT HUB CAP Check hub face is clean Fit the hub cap gasket and the hub cap Fig 28 FIG 28 Tighten the bolts evenly Finally tighten the hub cap screws to the torque value specified in table 1 Page 9 Fig 29 Care should be taken not to damage any of the sealing lips on the gasket FIG 29 6 ArvinMeritor brand TA amp TAC Service TA amp TAC Service Section 4 Hub and Rotor Service for Disc Brakes TA amp Service SECTION 4 Hub Recognition There are two basic hub types for the TA Disc Brake Axle series dependant on wheel type See Figs 1A and 1B Either type can be obtained in separate bearing TA or cartridge bearing TAC format FIG 1A FIG 1B Fig 1A Hub type for SINGLE WHEEL WITH DISC BRAKE Fig 1B Hub type for TWIN WHEEL WITH DISC BRAKE TAC with disc brakes The TAC hub and bearing assembly is fully sealed and can normally be left undisturbed for a 7 year or 1 million km whichever is soonest maintenance free period The TAC axle fitted with D Duco disc brakes would normally only require hub removal when it is necessary to change the disc rotor Hub and Bearing Removal and Inspection TA amp TAC The hub removal service and re fitting procedures are similar to those described in Section 3 However in the case of disc brake installations
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