Specifications

Prepare Parts for Reassembly
32 MAINTENANCE MANUAL
Welding on Axle Housings
WARNING
Wear safe clothing and eye protection when
you use welding equipment. Welding equip-
ment can burn you and cause serious personal
injury. Follow the operating instructions and
safety procedures recommended by the weld-
ing equipment manufacturer.
Axle weld locations and welding procedures
must adhere to Meritor standards. Welding at
locations other than those authorized by Meri-
tor will void the warranty and can reduce axle
beamfatigue life. Serious personal injuryand
damage to components can result.
Seer to Maintenance Manual number 8, on the
Drive Axle Housings. To obtain this publication,
see to the Service Notes page on the begin of
this manual.
Meritor permits drive axle housing assembly re-
pair welding in the following locations only.
• Housing-to-coverweldjoints;
• Snorkelwelds;
• Housing seam welds between the suspen-
sion attaching brackets
• Bracketweldingtothedriveaxlehousing
Prepare the Axle
WARNING
The high temperature caused by the open
ame from the cutting torch can ignite the oil
in the axle housing and can cause serious per-
sonalinjury.
1. Remove the oil drain plug from the bottom of
the axle housing and drain the lubricant from
the assembly.
CAUTION
REMOVE THE DIFFERENTIAL FROM THE
AXLE HOUSING BEFORE YOU WELD ONTO
AN AXLE. DO NOT WELD FOR AXLE WITH
THE DIFFERENTIAL INSTALLED. ELECTRI-
CAL ARC AND DAMAGE TO COMPONENTS
CAN RESULT.
CAUTION
REMOVE THE BRAKE AIR CHAMBERS BE-
FORE YOU WELD ONTO AN AXLE. DO NOT
EXPOSE A BRAKE AIR CHAMBER TO MORE
THAN 250°F (121°C). DAMAGE TO THE AIR
CHAMBER CAN RESULT.
3. Remove the wheel-end components and
brake air chambers from the axle. See to the
correct Meritor brake maintenance manual or
the vehicle manufacturer’s instructions.
4. For housing to cover welds, clean the outside
housing-to-cover weld area 2 at 3 -inches
(50.8-76.2 mm) past each end or side of the
crack. Clean the inside area where the cover
mates with the housing. Clean the area com-
pletely around the cover. Use a wire brush
and a cleaning solvent that will remove dirt
and grease from these areas.
5. For suspension bracket welds, clean both
lower and upper suspension brackets and
the areas of the axle housing around each
bracket. Use a wire brush and a cleaning
solvent that will remove dirt and grease from
these areas.
WARNING
The axle housing must be 70°F (21°C) or
warmer before you weld onto the axle. Do not
weld onto a cold axle or weld cold parts onto an
axle. Cracks in the weld area, damage to com-
ponentsandseriouspersonalinjurycanresult.
6. Ensure that the axle housing temperature
measures 70°F (21°C) or warmer.
• If the axle housing temperature measures
less than 70°F (21°C): Store the axle in a
heated room until the housing reaches the
correct temperature.
7. Heat the damaged area to approximately
300°F (149°C) before you begin welding.
8. Use suitable weld wire electrodes when you
weld. Suitable weld wire electrodes include ei-
ther BS EN 499 – E 42 2 B 32 H5 or BS EN
440 – G 42 2 M GSi (American Welding Society
equivalents E7018 and ER70S3, respectively).
2. Remove the differential assembly from the
axle housing. See the correct Meritor dif-
ferential maintenance manual or the vehicle
manufacturer’s instructions.