SB-10054901-1529

Retrofit Guidelines
Hazard Alert Messages
WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.

TP-13122
Issued 01-14

Replacing the Carrier on Certain
Meritor RR/RS/RC 160 Series
Axles
Issued
1TP-13122
Technical
01-14
Bulletin

4.

The repair facility must package the carrier and have it ready to
ship. The yellow return tag and the OnTrac Worksheet included
in this bulletin must be attached to the carrier.

How to Obtain Complete Carrier
Removal and Installation Procedures
Refer to Maintenance Manual 5A, Single Reduction Differential
Carriers.
To access this publication, visit the Literature on Demand section at
meritor.com.

Use a brass or synthetic mallet for assembly and disassembly
procedures. Do not hit steel parts with a steel hammer. Pieces
of a part can break off. Serious personal injury and damage to
components can result.

KIT FRK 13-CARRKIT Carrier
Replacement Kit

Purpose of This Bulletin

Description

Quantity

Carrier

1

Carrier Installation Kit (FRK 13-10152 or
FRK 13-10153)

1

This bulletin provides guidelines required to perform the retrofit
repair that includes removing and replacing carriers on certain
Meritor RR/RS/RC 160 Series axles using the kits and instructions
specified below.

Repair Guidelines
1.

Contact the Meritor OnTrac™ Customer Call Center for
assistance to identify and order the appropriate repair kit.
앫 Phone 866-668-7221
앫 Email ontrac@meritor.com
앫 Fax 248-435-5580

2.

Once you receive the parts, promptly schedule the repair with
the end user.

3.

When the carrier has been replaced, contact the Meritor
OnTrac™ Customer Call Center to update the case. An OnTrac
representative will schedule the carrier return and supply an
authorization code for submitting a claim.

Table A: Kit FRK 13-CARRKIT

KIT FRK13-10152 and KIT
FRK13-1-153 Installation Kits

2.

Use a jack or other lifting tool to raise the vehicle so that the
wheels to be serviced are off the ground. Support the vehicle
with safety stands. Figure 1.

Table B: Kits FRK 13-10152 and FRK 13-10153

3.

Place a drain pan under the rear axle.

4.

Remove the plug from the bottom of the axle housing. Drain
the lubricant from the assembly into a clean container so it can
be reused during reassembly.

FRK
13-10152
(164 Axes,
With Dowels)
Description
Axle shaft
Gasket

Part
Number
2208E1123

Carrier to
Housing Kit

FRK
13-10153
(160/161
Axles,
Without
Dowels)

Quantity
2

2

KIT 4289

KIT 4304

1-3/4″ Bolt

10X1594

5

2″ Bolt

10X1595

3

3-1/2″ Bolt

10X1600

3

4-1/4″ Bolt

10X1767

1

Dowel

1246V1166

4

1229W1557

12

12

2297A7021

1

1

Washer


Loctite
5699
Sealant

NOTE: Before the axle shafts and differential carrier can be
removed or installed, the driver-controlled differential lock
(DCDL), if equipped, must be shifted into and held in the locked
or engaged position. The locked position gives enough
clearance between the shift collar and the axle housing to
permit the removal or installation of the axle shafts and carrier.
Refer to Maintenance Manual 5A for DCDL service information.
5.

Disconnect the driveline universal joint from the pinion input
yoke or flange on the carrier.

6.

Remove the capscrews and washers or stud nuts and washers,
if equipped, from the flanges of both axle shafts.

7.

Loosen the tapered dowels, if equipped, in the axle flanges of
both axle shafts. Refer to Maintenance Manual 5A for axle
shaft removal procedures.

8.

Remove the axle shafts from the axle housing.

9.

Loosen the carrier-to-housing fastener at the 12 o’clock
position and leave attached to the assembly. The fastener will
hold the carrier in the housing.

8

4

Service Repair Time

10. Remove all other fasteners and tapered dowels, if equipped.

The standard OEM labor time for carrier R&R will be added for each
vehicle to support the repair.

11. Install two long guide studs at the 1 and 11 o’clock positions.

Procedures
Carrier Removal
1.

Wear safe eye protection. Park the vehicle on a level surface.
Block the wheels to prevent the vehicle from moving. Figure 1.

12. Loosen the differential carrier in the axle housing. Use a leather
mallet to hit the mounting flange of the carrier at several
points.
13. Install a hydraulic roller jack or other lifting device to the carrier.
Figure 2.
Figure 2

Figure 1

WOOD
BLOCK

ROLLER
JACK

SAFETY
STANDS
1002983b

1002709c

Figure 2

Figure 1
TP-13122
Issued 01-14
Page 2

Copyright Meritor, Inc., 2014

(16579)
Printed in USA

14. Remove the loose fastener at the 12 o’clock position.

Figure 4

Remove old
sealant material.

CAUTION
When you use a pry bar, be careful not to damage the carrier
or housing flange. Damage to these surfaces will cause oil
leaks.
Use care when handling the carrier to ensure the ring gear
does not become damaged.

HOUSING AND
CARRIER SHOWN

15. Remove the carrier from the axle housing. Use a pry bar that
has a round end to help remove the carrier from the housing.

1003027a
Figure 4

Carrier Installation
1.

3.

WARNING

CAUTION
When you clean the silicone from the mounting surfaces, use a
non-abrasive disk on the rotary tool and keep it perpendicular
to the housing and carrier face. Take care to ensure you do not
remove the base housing flange material. Use care especially
at the 6 o’clock position where most leaks occur and where
there is the least amount of housing and carrier surface area.
A leak can result in damage to components.
2.

Remove metal filings from the magnets inside the housing.

Remove all debris from inside the housing.

Use a rotary tool with a scour pad to clean all silicone residue
from the housing and carrier faces. Figure 3. Surfaces must be
clean, dry and free of contaminants. The surfaces must not be
oily to the touch. Figure 4.

Figure 3

Clean the housing face with a rotary tool and a
scour pad. Keep the tool perpendicular to the surface.

CORRECT
HOUSING
FACE

ROTARY TOOL

INCORRECT
HOUSING
FACE

Solvent cleaners can be flammable, poisonous and cause
burns. Examples of solvent cleaners are carbon tetrachloride,
and emulsion-type and petroleum-base cleaners. Read the
manufacturer’s instructions before using a solvent cleaner,
then carefully follow the instructions. Also follow the
procedures below.
앫 Wear safe eye protection.
앫 Wear clothing that protects your skin.
앫 Work in a well-ventilated area.
앫 Do not use gasoline, or solvents that contain gasoline.
Gasoline can explode.
앫 You must use hot solution tanks or alkaline solutions
correctly. Read the manufacturer’s instructions before
using hot solution tanks and alkaline solutions. Then
carefully follow the instructions.
4.

Use solvent to clean the inside of the housing.

5.

Use Loctite ODC Free cleaner or brake cleaner to clean the
housing and carrier faces.

6.

Dry the housing and carrier faces.

7.

Use a tap to clean the internal threads in the housing.

ROTARY
TOOL
4007816a

Figure 3

(16579)
Printed in USA

Copyright Meritor, Inc., 2014

TP-13122
Issued 01-14
Page 3

WARNING
When you apply some silicone gasket materials, a small
amount of acid vapor is present. To prevent serious personal
injury, ensure that the work area is well-ventilated. Read the
manufacturer’s instructions before using a silicone gasket
material, then carefully follow the instructions. If a silicone
gasket material gets into your eyes, follow the manufacturer’s
emergency procedures. Have your eyes checked by a
physician as soon as possible.

11. If the carrier has tapered holes, install the tapered dowels,
washers and corresponding 5/8″ X 2.0″ (10 X 1595)
capscrews at the tapered dowel locations on the standard
thickness carrier flange surface. Figure 6.
Figure 6

REAR CARRIER TAPERED DOWEL LOCATIONS
TOP
1
4

Take care when you use Loctite adhesive to avoid serious
personal injury. Read the manufacturer’s instructions before
using this product. Follow the instructions carefully to prevent
irritation to the eyes and skin. If Loctite adhesive material
gets into your eyes, follow the manufacturer’s emergency
procedures. Have your eyes checked by a physician as soon as
possible.

CAUTION
Apply silicone gasket material in a continuous 0.25-inch
(6 mm) bead. If you use more than this amount, gasket
material can break off and plug lubrication passages. Damage
to components can result.
8.

Apply a 0.25-inch (6 mm) bead of Loctite 5699 silicone
gasket material to the housing face. Do not use ThreeBond
1216E silicone products. Figure 5.

3

2

4005373b

Figure 6

12. Install the remaining capscrews. Use a crossing pattern to
tighten the capscrews evenly to 225 lb-ft (306 N폷m). @
13. Clean the mating surfaces of the axle shaft and the wheel hub.
14. If silicone gasket material is used, apply a 0.125-inch diameter
(3 mm) bead of the gasket material around the mating surface
of the hub and around the edge of each fastener hole in that
surface.
If a gasket is used, install the gasket and the axle shaft into the
housing. The gasket and the flange of the axle shaft must fit
flat against the wheel hub. Figure 7.

Figure 5

Figure 7

SOLID TAPERED
DOWEL
AXLE
SHAFT

HARDENED
WASHER

0.25" (6 MM)
DIAMETER SILICONE
GASKET BEAD

HUB

HARDENED
NUT
4004435a
GASKET OR SILICONE
GASKET MATERIAL

Figure 5

4011153a

9.

If removed, reinstall two long studs into the housing to guide
the carrier into the housing.

10. Immediately install the carrier into the housing to permit the
silicone gasket material to compress evenly between the faces.
NOTE: Tapered dowels installed in the thick carrier flange
locations will be secured by the long capscrews in KIT 4289.

TP-13122
Issued 01-14
Page 4

Figure 7

15. If the axle shaft uses tapered dowels, install solid tapered
dowels over each stud and into the flange of the axle shaft. Use
a punch or a drift and hammer, if necessary.
16. Install the Grade 8 nuts and hardened washers on the stud.
Lock washers are an acceptable alternative. Tighten the stud
nuts in sequence shown in Figure 8 to the specified torque. @

Copyright Meritor, Inc., 2014

(16579)
Printed in USA

Figure 8

8

1

6

3

4
5
2

7

4000663a

Figure 8

17. Wait a minimum of 60 minutes before filling the assembly with
lubricant. Fill the axle housing using the same lubricant that
was removed previously. Ensure the lubricant level is level with
the bottom of the fill hole and add lubricant if necessary.

Meritor Heavy Vehicle Systems, LLC
2135 West Maple Road
Troy, MI 48084 USA
866-OnTrac1 (668-7221)
meritor.com

Information contained in this publication was in effect at the time the publication was approved for printing and is subject to
change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the information presented or
to discontinue the production of parts described at any time.
Copyright 2014
Meritor, Inc.
All Rights Reserved

Printed in USA

TP-13122
Issued 01-14
(16579)

TP-0753
Revised 05-13

Carrier-to-Housing Joint Repair
Procedure

Technical Bulletin

All Meritor 120, 145, 160, 180, 380 and
MT-14X Series Axles
Revised
1TP-0753
Technical
05-13
Bulletin

Axles Covered in This Bulletin

Table B: KIT 4302 (For Rear Carriers)
Contents

Description

Quantity

All Meritor 120, 145, 160, 180, 380 and
MT-14X Series Axles

10 X 1594

Capscrew

8

10 X 1597

Capscrew

4