TP-0838

Issued 02-08

How to Analyze Contaminants on

Issued
1TP-0838
Magnetic Drain and Fill Plugs
Technical
02-08 Bulletin

Technical Bulletin

Hazard Alert Messages Remove and Inspect the Magnetic

Read and observe all Warning and Caution hazard alert messages in Fill/Drain Plug
this publication. They provide information that can help prevent Remove the magnetic fill/drain plug. Inspect the metal particles
serious personal injury, damage to components, or both. adhering to the plug. Use the Guidelines in this technical bulletin to
determine if the metal particles you find are fine (a normal condition)
WARNING or larger (a condition that is not normal).
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
Guidelines
Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving. Support the vehicle with
Fine Metal Particles
safety stands. Do not work under a vehicle supported only by The fine metal particles attached to the magnetic plug in Figure 1
jacks. Jacks can slip and fall over. Serious personal injury and are normal. Internal components can shed fine metal wear particles
damage to components can result. at a steady rate, especially during the break-in period. In addition to
the magnetic plugs, Meritor axles are also equipped with four to six
How to Obtain Additional Maintenance magnets in the housing to capture debris generated during
extended maintenance intervals used today.
and Service Information
Refer to Maintenance Manual 1, Preventive Maintenance and Figure 1

Lubrication; and Technical Bulletin TP-9539, Approved Rear Drive

Axle Lubricants. To obtain these publications, visit Literature on
Demand at arvinmeritor.com.

Metal Particles on the Magnetic

Fill/Drain Plug
During maintenance procedures it is normal to find fine metal
particles adhering to the magnetic fill/drain plug. These particles are
4006879a
generated under normal operating conditions, and the magnets
attract the particles and prevent them from passing through the gear Figure 1
mesh or bearings.
However, larger metal particles adhering to the fill/drain plug, such Thrust Washer Fragments
as gear teeth, bearing fragments, thrust washer fragments and Figure 2 shows a main differential side gear thrust washer fragment.
metal shavings, are not a normal condition.
The loss of a fragment from the thrust washer is not detrimental to the
It is important to be able to identify the differences between fine and operation of the axle and does not require disassembly, inspection and
large metal particles to determine how they occurred and what replacement of the axle.
repairs may be required to prevent component damage.
If you are concerned about additional fragments or component Figure 4

damage, perform an oil sample analysis. If the iron content of the

sample is above 1000 parts per million (ppm), inspect and repair the
carrier as necessary.

Figure 2

4006881a
THRUST
WASHER Figure 4
FRAGMENT

Figure 5

4006880a

Figure 2

Metal Shavings
Figure 3 shows metal shavings which are remnants from the
housing machining process. Metal shavings adhere to the magnets
and are not detrimental to the operation of the axle. It is not
necessary to perform further inspections or remove the carrier for
4006882a
cleaning.
Figure 5
Figure 3

Verify the Lubricant Level is Even With the

Bottom of the Fill Plug Hole
Verify that the lubricant is even with the bottom of the fill plug hole
and not below the fill plug hole. If necessary, add the specified
lubricant, until it is even with the bottom of the fill plug hole.
Figure 6.

Figure 6

4006883a
Oil level must be even with
bottom of fill plug hole.
Figure 3

Bearing and Gear Tooth Fragments

Figure 4 and Figure 5 show bearing and gear tooth fragments. Both
indicate a significant issue that can result in component damage.
Immediately remove the carrier, inspect it, and perform required
repairs.
FILL PLUG

4004601a

Figure 6

TP-0838
Issued 02-08 (16579/22882)
Page 2 Copyright ArvinMeritor, Inc., 2008 Printed in USA
Check the Condition of the Oil Copper (Sample Not Shown)
Most drive axle oils are either golden brown or deep red in color. If A copper color indicates that the drive helical support thrust washer
the oil looks “milky brown” or has a “copper” color, the oil is may have disintegrated. Use care when you evaluate the oil, as a
contaminated. copper color can be confused with the normal color of some oils.
Perform a lubrication analysis to determine the amount of copper in
The oil samples in Figure 7 show how the lubricant may appear the lubricant before you perform a physical inspection.
during inspection. Refer to Oil Conditions for guidelines.
앫 If the copper level is above 600 ppm: Remove the input shaft
Figure 7
assembly and inspect the drive helical support thrust washer.
앫 If the copper level is 600 ppm or below: You can continue to
1 2 3 4
use the oil.

Used-Oil Analyses (ppm = parts per million)

Iron (Fe) If the level is 1000-1500 ppm,
resample the oil. If resampling
indicates that the iron level is above
1000 ppm, drain and replace the oil.
4006885b If the level is above 1500 ppm, drain
and replace the oil.
Figure 7
Silicon (Si) If the level is greater than 100 ppm,
drain and replace the oil.
Oil Conditions
If the level is greater than 0.3%, drain
Water (H2O)
Sample 1: Red and replace the oil.

Sample 2: Golden Brown Phosphorus (P) If the level is less than 900 ppm, it is
possible that the oil is not a GL-5 gear
Both the red and golden brown samples show the typical oil. Contact the lubricant manufacturer
appearance of new GL5 EP oils that meet the SAE J2360 or Meritor Materials Engineering to
specification. They usually are golden brown, but also can be red in determine the expected phosphorus
color. Figure 7. level of a new oil sample. Only GL-5
type gear oils are approved for use in
Sample 3: Black
Meritor differentials.
This black sample is used-oil with significant time and mileage. The
Toluene Insolubles If the level is greater than 0.100 wt.%,
color change from red or golden brown to black is the result of a
drain and replace the oil.
normal chemical process that occurs as the additive package in the
oil degrades. The black color does not necessarily indicate that the
oil’s useful life has been exhausted. Perform a lubrication analysis to
verify that the oil can still be used in the carrier. Figure 7.

Sample 4: “Milky” Brown

This “milky” brown sample indicates the oil is contaminated with
significant moisture well above the allowable change specification of
>0.3%. Change the oil immediately. Also try to determine how the
moisture entered the assembly and consider extending the
breathers on applications where this occurs. Figure 7.

TP-0838
(16579/22882) Issued 02-08
Printed in USA Copyright ArvinMeritor, Inc., 2008 Page 3
Meritor Heavy Vehicle Systems, LLC Information contained in this publication was in effect at the time the publication was approved for printing and is subject to
2135 West Maple Road change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the information presented or
Troy, MI 48084 USA to discontinue the production of parts described at any time.
800-535-5560
Copyright 2008 TP-0838
arvinmeritor.com
ArvinMeritor, Inc. Issued 02-08
All Rights Reserved Printed in USA (16579/22882)