•

Steam cleaning of the housing is not necessary.

•

Removal of the hubs is not necessary.

2. If significant metal debris is found in the housing, document the debris with
photos, and proceed as instructed by OnTrac.
•

Document with photos.

•

Inspect the hub bearings per the Bearing Inspection instruction found in the
A001 bulletin attachments.

•

Clean the four magnets in the carrier housing and the magnets on the drain and
fill plugs.

•

Thoroughly clean the inside of the axle housing, ensuring that all debris is
removed. The baffles inside the axle housing trap debris; this may include steam
cleaning if necessary.

Paint the Carrier and lock nuts

Prime and paint the new carrier and fasteners to match the color of the original parts.

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REPAIR PROCEDURE
Install the Differential Carrier
CAUTION

When you clean the silicone from the mounting surfaces, use a rotary tool with a
mild, non-abrasive pad. Keep the pad 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.
1. Use a rotary tool with a mild, non-abrasive pad to clean all silicone residue from
the housing and carrier faces. A 3M Brand Scotch-Brite™ Roloc™ green bristle
disc is recommended for cleaning to ensure no damage occurs to the housing and
carrier surfaces. Surfaces must be clean, dry, and free of foreign matter. The
surfaces must not be oily to the touch.

2. Clean metal filings from all the magnets; including the four magnets inside the
housing and the magnets on the fill and drain plugs.

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REPAIR PROCEDURE
3. Clean and remove all debris from inside the axle housing before you install the
new carrier.

Warning
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, and
then carefully follow the instructions. Also, follow the procedures below.
Wear safe eye protection.
Wear clothing that protects your skin.
Work in a well-ventilated area.
Do not use gasoline or solvents that contain gasoline. Gasoline can explode.
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.
CAUTION

New capscrew kits have blue Dri-Loc® STS threadlocker, an equivalent to
Loctite® 242 threadlocker, applied to the capscrews. Do not remove the blue DriLoc® STS threadlocker from the capscrews. Damage to components can result.

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REPAIR PROCEDURE
7. Use a 5/8 in.-18 tap to clean the internal threads in the housing.

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, and 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.

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 continuous 0.25-inch (6 mm) bead of Loctite® Ultra Grey sealant to the
housing face. Do not use ThreeBond 1216E silicone products.

9. Install two temporary alignment studs in the housing (at the 2 o’clock and 10
o’clock positions) to guide the carrier into the housing. Tighten the studs until
there are no exposed threads.
CAUTION

Do not use a hammer or mallet to install the carrier. A hammer or mallet will
damage the mounting flange of the carrier and cause oil leaks.

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REPAIR PROCEDURE
10. Use a hydraulic roller jack or a lifting tool to install the carrier into the axle
housing.

11. Immediately install the carrier into the housing to enable the silicone gasket material
to spread evenly between the faces.
12. Install the capscrews and washers as follows.

a. In a crisscross pattern to evenly tighten the capscrews to 80-100 lb-ft (109136 N·m).
b. Tighten all the capscrews in a crisscross pattern to a torque specification of
225 lb-ft (305 N·m) (range 190-240 lb-ft [258-325 N·m]).
13. Wait a minimum of 60 minutes before filling the assembly with oil. After the
appropriate waiting period, fill the axle with specified oil.

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REPAIR PROCEDURE
14. Install the yoke.

NOTE
Sometimes the sleeve from the previous seal will stay on the yoke journal during
removal. Ensure that the seal sleeve is removed from the yoke before you install the
yoke.

a. Use a special yoke/flange driver tool, tool kit number MST-YT114, to
install the yoke or flange. DO NOT use the new nut to draw on the yoke or
flange. The yoke or flange must be seated against the outer bearing. Use
the alternative procedure below if the tool is not available.

Alternative yoke installation method if the yoke/flange driver tool is not available
The prevailing torque feature of the yoke nut affects the torque applied during
installation. An alternative to prevent this torque loss during installation is to machine
the prevailing torque feature off an old nut then use this altered nut to draw on and
seat the yoke.
a. Machine off the four outboard threads of the nut as shown in the illustration
below. Keep altered nut for future yoke installation needs.

b. Push the yoke on as far as possible by hand and then install the modified
nut.

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REPAIR PROCEDURE
c. Install a yoke bar or other suitable tool to hold the yoke in place.

d. Tighten the nut until the yoke or flange is seated against the outer bearing.
e. After the yoke is seated with the altered nut, remove the nut, and then
continue with this procedure.
15. Install a yoke bar or other suitable tool to hold the yoke in place.

NOTE
It is standard practice to install a new yoke nut and washer whenever the yoke nut is
removed.

16. Apply Loctite® 270 or 277 adhesive sealant in a 0.12-inch (3.1 mm) bead around
the inside diameter of the new yoke nut. Install the new washer and yoke nut onto
the input shaft and tighten to a torque specification of 825 lb-ft (1085 N·m) (range
750-850 lb-ft [1020-1150 N·m]).

Install the Axle Shaft

1. Install the axle shaft gaskets
2. Install the axle shafts, washers, and new lock nuts.
3. Torque the lock nuts in a crisscross pattern to 150-190 lb-ft. (203-258 N·m.).
4. Ensure that the hub fill plug is in a horizontal position.
5. Top off the oil in each hub.

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REPAIR PROCEDURE
6. Check and top off the oil in the axle sump. The oil level should be at the level of the
fill plug in the bowl of the housing.
7. If replaced per above guidance, package the removed axle shaft and carrier for pick
up.
8. Complete the claim submittal.

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Service Inspection Procedure

A001

Section
022- Drive Axles

Release Date
5/25/2017

Warranty
Peterbilt will pay for parts at dealer net plus applicable mark-up and labor through 06/01/2018:



ALL CLAIMS MUST INCLUDE the OnTrac# as provided by Meritor.



0.7 hours labor to inspect the axle, reinstall the axle, and paint the axle lock nuts. File a long
form claim using SRT 00A-001 for the inspection. Claim must include OnTrac # as provided by
Meritor. Enter A001 in the appropriate field.



0.5 hours labor to drive the vehicle to obtain a minimum of 15 miles on the odometer for trucks
that are Not In Service (NIS). File a long form claim using SRT 022-997.



4.4 hours labor to inspect the axle, remove the carrier assembly, clean the housing-including
steam clean as necessary, paint the new carrier, paint the new axle flange, paint the new axle
lock nuts, and install the carrier and axles. File a long form claim using SRTs 022-053 (3.8
hours) and 053-990 (.6 hours). Claim must include OnTrac# as provided by Meritor. Enter A001
in the appropriate field.

NOTE: Peterbilt dealers may perform A001 repairs on Kenworth chassis, but Quick Claims do not
apply. For Kenworth chassis repairs, use the long claim input form in DWWC selecting "Draft/Offline
Claims," the "General" tab, and in the "Type of Claim" drop down box, select "PACCAR Engine
Claim," then manually enter claim codes (A001 #, Failure type, and SRT).

For Field...

Enter...

Failure Location

022-002-001

Failure Type

700

Claim Type

A

Responsibility

09

SRT 00A-001

0.70 hours labor to inspect and reinstall the axle

SRT 022-997

0.50 hours labor to drive the vehicle to

SRT 022-053

3.80 hours labor to inspect the axle, R&R the carrier
assembly, drain, clean and refill.

SRT 022-990

0.6 hours labor to paint carrier and axle.

Parts
PACCAR Parts Customer Service will be in contact with your dealership’s Parts Manager to provide the
required parts needed to service your customers for this inspection. The carriers, axle shafts, and
reseal kits are on reserve and cannot be purchased through normal methods. These parts cannot be
ordered without contacting PACCAR Parts Customer Service and providing a Meritor OnTrack case
number.
To better service the impacted customers for your service area location there will be a required initial
stocking order a pre-determined number of carriers, axle shafts, and re-seal kits—(the quantity will be
managed jointly through PACCAR Parts and Meritor) that PACCAR Parts will work with you to place the
order. This order will be expedited to ensure you have pre-stock on hand before your customers will
be contacted to schedule the service inspection process and possible repair with your dealership.
Standard PDC orders may be placed for the inspection parts listed below if stock is needed.
Table 1 Parts Required for Inspection

Quantity Part Number

Description

1
8
8
As needed.
Should be 1
qt. or less.
Up to 1 pt.
Up to 1 pt.

03-01568
1229W1661
HWU05665
Source locally

Axle Shaft Gasket
Washer (axle shaft fastener)
Lock nut (axle shaft fastener)
Oil as indicated on the axle tag.

Source locally
Source locally

Primer for lock nuts
Paint for lock nuts

PACCAR Parts will automatically generate XE orders for parts with an * after the part number for each
servicing dealer location. All parts with an * require an OnTrac case number to be ordered. Standard
PDC orders may be placed for the remaining parts listed below if stock is needed.
Table 2 Parts Required for Repairs

Quantity Part Number

Description

1

C87-6002-0XXX*

1
1
2
16
16
As needed
(Axle sump
requires 9.8

C65-6035-02611*
C74-6062*
03-01568
1229W1661
HWU05665
Source locally

Carrier Assembly
Where “XXX” is the ratio. Example C876002-0247
Axle shaft
Re-seal kit
Axle Shaft Gasket
Washer (axle shaft fastener)
Lock nut (axle shaft fastener)
Top off oil for the hubs and axle sump. As
indicated on the axle tag.

Quantity Part Number
qts)
Up to 1 qt.

Source locally

Up to 1 qt.

Source locally

Description
Primer for carrier, axle flange, and lock
nuts
Paint for carrier, axle flange, and lock nuts

Procedure
Service all chassis affected that enter your dealership, even if the customer has no issue with the
chassis.
1.

Review the attached chassis list for your dealer code and schedule your customer(s) for
service if their chassis is on the list.

2.

Review the DWWC or SIR for “Complete” next to the “A001” code prior to performing this
repair.

3.

Follow the procedures below to inspect for damage and repair as needed.

This inspection needs to be completed as soon as possible.
1. Contact the PACCAR Parts line at 1-800-944-0251. Select option 4 for PACCAR Axles. You will be
routed to a Meritor representative. Provide the Meritor representative with the VIN #, axle serial #,
and mileage to confirm that the unit requires inspection. The call center will provide a case # for
tracking purposes.
·

The axle assembly serial number can be found on a metal tag on the leg of the
housing adjacent to the carrier.

2. Assure that the dealer stock items in Table 1 Parts required for Inspection are on hand
prior to starting the inspection.
3.

Use the procedure in the attachments section to inspect and/or repair the axle assembly.
There are three possible scenarios you may encounter with this inspection.




Axle shaft is not contacting the spider shaft.
Axle shaft is contacting the spider shaft, but there is only rubbing
damage. Metal debris is isolated to the carrier area of the axle housing.



Axle shaft is contacting the spider shaft and the spider shaft and/or
carrier is damaged. Metal debris may be spread through the axle
housing and may require extensive cleaning and possible hub
replacement.

Attachments
Go to this link for Chassis and Parts list and Procedure: A001 Rear-Rear Axle Inspection