22E027 – Rear Axle Drive Pinion May Fracture – Meritor 180 Series Drive Pinions

SEOCONTENT-START

1
May 13, 2022
TOR Truck USA Inc.
207 Lynndale CT
Suite B
Mechanicsburg, PA 17050
IMPORTANT SAFETY RECALL
NHTSA File: 22E027
Dear CUSTOMER CONTACT:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Meritor, Inc. (“Meritor”) has decided that a defect which relates to motor vehicle safety exists in certain 180 Series Drive Pinions shipped to our aftermarket customers. The production date range of the suspect pinions is June 30, 2020 through March 3, 2022.
Description of Defect
Certain 180 Series Drive Pinions with low mileage (below 33,954 miles in linehaul vehicles and below 8,496 miles in non-linehaul vehicles) may fracture in the spline. In vehicles with susceptible air brake hose routings, a fractured pinion may allow for axial separation of the fractured portion of the pinion shaft and yoke which can allow them to hit the brake drop hose, causing air to leak from the hose. If this occurred, it would unintentionally apply the parking brakes without the brake lights coming on, possibly resulting in crash.
How do I know if I have suspect equipment?
If you are receiving this letter, suspect components (either differential carrier(s) and/or gear set(s)) were shipped to your address.
How do I resolve this safety recall?
If you are receiving this letter, suspect components (either differential carrier(s) and/or gear set(s)) were shipped to your address as replacement parts. We ask that you contact Meritor’s Aftermarket Warranty department regarding this recall.
2
Contact Details
Aftermarket Warranty Customer Service Center – Florence KY
Email: aftermarketwarranty@meritor.com
U.S. Telephone Number 888.725.9355
Canada Telephone Number 800.387.3889
Installed Components: if suspect components were installed in a vehicle, please provide the following information:
• A photo as indicated in page 5 (this recall only applies to carriers installed on vehicles having the airline routing of concern)
• Meritor’s recall number 22E-027
• Current Vehicle Mileage
• Model Number and Serial Number
• Purchase Order Number / Invoice Number (Used to purchase product)
• Date component received
• An installation or repair record that includes:
o Full Vehicle VIN
o Install Date
o Vehicle Mileage at Installation
If the vehicle contains the equipment included in this recall, Meritor will order the replacement parts to be shipped to a preferred repair facility. All repairs will be provided to you free of charge. Please note that this repair is estimated to take 6 hours to complete.
Once the parts are received at the Repair Facility, they should contact you to schedule the appointment. When the replacement is complete, the repair facility will need to report completed work, date of repair along with some of your customer information to provide reimbursement to the repair facility for additional expenses.
Please note that we estimate the repair will take 6 hours. We realize this is less than ideal so please schedule appropriately.
3
Uninstalled Components Stored in Inventory: If the suspect components have not been installed into a vehicle and remain in your inventory, please provide Meritor with the following information prior to installation.
• A photo or other identification of the intended install vehicle as indicated in page 5 (this recall only applies if carriers are to be installed on vehicles having the airline routing of concern)
• Meritor’s recall number 22E-027
• Model Number and Serial Number
• Purchase Order Number / Invoice Number (Used to purchase product)
• Date component received
Note: If uninstalled components were sold by you to customers, please send this notification to those customers.
What if I already paid to have this repair completed?
Contact Meritor with the details of the repair including repair shop, repair date, and an invoice. Once we have received proof of completion and your invoice, Meritor will coordinate appropriate reimbursement.
Communication
If you have any questions or concerns, please contact Meritor Warranty Customer Service Center at (U.S. 888.725.9355) or (Canada 800.387.3889) and one of our representatives will be happy to assist you.
If you conclude that Meritor has not enabled you to remedy this condition in a reasonable time, you may submit a complaint to the:
Administrator
National Highway Traffic Safety Administration
1200 New Jersey, SE
Washington, D.C. 20590
– or –
Call the toll-free Vehicle Safety Hotline: 1-888-327-4236; (TTY: 800-424-9153) or go to http://www.safercar.gov
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We regret any inconvenience that this situation may cause. Meritor wants to assure you that we are concerned for customer safety and your continued satisfaction with our products.
Sincerely,
Randy Paul
Director of Quality
Meritor, Inc.
Enclosures:
5
Photograph Details
Photos are mandatory for Meritor to determine if the vehicle is part of the recall

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-027
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Meritor, Inc.
Submission Date : MAY 09, 2022
NHTSA Recall No. : 22E-027
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Meritor, Inc.
Address : 2135 West Maple Road
Troy MI 48084
Company phone : 248-435-1725
Population :
Number of potentially involved : 536
Estimated percentage with defect : 1 %
Equipment Information :
Brand / Trade 1 : Meritor
Model : Drive Pinion 180 Series
Part No. : 180 Drive Pinion
Size : NR
Function : Transmit Torque
Descriptive Information : Some 180 Series Drive Pinions with low mileage (below 33,954 miles in linehaul
vehicles and below 8,496 miles in non-linehaul vehicles) may fracture in the
spline. The production date range of the suspect pinions is June 30, 2020
through March 3, 2022. The recalled population does not differ from products
built prior to June 30, 2020. However, Meritor believes that products built prior
to that date would have already failed if they had the defect. Products
manufactured after March 3, 2022 have had both a manufacturing and an
inspection process change. On February 18, 2022, Meritor changed its
production process to eliminate the straightening of pinion shafts. Shafts that do
not meet the specifications for straightness are not straightened or used. On
March 3, 2022, Meritor validated new design dummy yokes on the assembly line
and began 100% testing of the pinions with both an eddy current in-process
inspection and an ultrasonic inspection at final. This 573 Safety Defect Report is
specific to product shipped to Meritor’s aftermarket customers only.
Production Dates : JUN 30, 2020 – MAR 03, 2022
Description of Defect :
Description of the Defect : 180 Series Drive Pinion fractured in the spline
FMVSS 1 : NR
FMVSS 2 : NR
Description of the Safety Risk : In pinions containing the defect, the fracture of the pinion shaft is expected to
Part 573 Safety Recall Report 22E-027 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Description of the Safety Risk : occur predominantly during a vehicle start-up at low speed (<10 mph) when
the maximum slip aligns with the maximum torque. The fracture location of
the pinion shaft occurs just over one inch from the thread end of the drive
pinion splines.In vehicles with susceptible air brake hose routings, a fractured
pinion may allow for axial separation of the fractured portion of the pinion
shaft and yoke which can allow them to hit the brake drop hose, causing the
hose to rupture. If this occurred, it would unintentionally apply the parking
brakes without the brake lights coming on, possibly resulting in a crash.
Description of the Cause : Meritor’s working theory is that the fracture in the drive pinion spline is
initiated during manufacturing in the straightening or bearing preload yoking
process. Meritor is currently not using the straightening process and Meritor is
currently conducting eddy current in-process inspection after the bearing
preload yoking process in addition to ultrasonic inspection at final for
containment as Meritor’s investigation continues.
Identification of Any Warning
that can Occur :
If the pinion fractures, the driver may hear an audible noise and feel the vehicle
slowing down due to loss of propulsion from the drive axle.
Involved Components :
Component Name : 180 Series Axle Carriers and Gear Sets
Component Description : Pinion
Component Part Number : 5-66167_02
Supplier Identification :
Component Manufacturer
Name : NR
Address : NR
NR
Country : NR
Chronology :
See attached word document titled “Chronology”
Part 573 Safety Recall Report 22E-027 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Meritor will work with the customer and an appropriate repair facility to
determine if the vehicle is affected. If repair is needed, the Differential
Carrier Assembly will be replaced. Gear Sets that were sold separately and
that have not yet been installed into a Differential Carrier Assembly will be
replaced with a new Gear Set. The replacement will be done at no charge
to the customer. Although Meritor believes all the customers that have
experienced the problem have been covered by our warranty, Meritor will
state in the §577 letter that if the customer has experienced the condition
and it was not covered under warranty, Meritor will reimburse the
customer for parts and labor connected with the replacement of the 180
Series pinion assembly.
How Remedy Component Differs
from Recalled Component :
The remedied component will meet Meritor’s straightness specifications
without having been subject to the straightening process, which is no
longer used. The remedied component will pass both eddy current and
ultrasonic inspection.
Identify How/When Recall Condition
was Corrected in Production :
On April 20, 2021, Meritor implemented ultrasonic testing at final
inspection. Meritor eliminated the straightening process on February 18,
2022. On March 3, 2022, Meritor validated new design dummy yokes on
the assembly line and began 100% testing of the pinions with both an eddy
current in-process inspection and an ultrasonic inspection at final.
Recall Schedule :
Description of Recall Schedule : Owners notifications will be sent to aftermarket customers affected by
the suspect population.
Planned Dealer Notification Date : MAY 01, 2022 – MAY 13, 2022
Planned Owner Notification Date : MAY 02, 2022 – MAY 13, 2022
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR
Address : NR
NR
Country : NR
Company Phone : NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-027
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Meritor, Inc.
Submission Date : MAR 29, 2022
NHTSA Recall No. : 22E-027
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Meritor, Inc.
Address : 2135 West Maple Road
Troy MI 48084
Company phone : 248-435-1725
Population :
Number of potentially involved : 536
Estimated percentage with defect : 1 %
Equipment Information :
Brand / Trade 1 : Meritor
Model : Drive Pinion 180 Series
Part No. : 180 Drive Pinion
Size : NR
Function : Transmit Torque
Descriptive Information : Some 180 Series Drive Pinions with low mileage (below 33,954 miles in linehaul
vehicles and below 8,496 miles in non-linehaul vehicles) may fracture in the
spline. The production date range of the suspect pinions is June 30, 2020
through March 3, 2022. The recalled population does not differ from products
built prior to June 30, 2020. However, Meritor believes that products built prior
to that date would have already failed if they had the defect. Products
manufactured after March 3, 2022 have had both a manufacturing and an
inspection process change. On February 18, 2022, Meritor changed its
production process to eliminate the straightening of pinion shafts. Shafts that do
not meet the specifications for straightness are not straightened or used. On
March 3, 2022, Meritor validated new design dummy yokes on the assembly line
and began 100% testing of the pinions with both an eddy current in-process
inspection and an ultrasonic inspection at final. This 573 Safety Defect Report is
specific to product shipped to Meritor’s aftermarket customers only.
Production Dates : JUN 30, 2020 – MAR 03, 2022
Description of Defect :
Description of the Defect : 180 Series Drive Pinion fractured in the spline
FMVSS 1 : NR
FMVSS 2 : NR
Description of the Safety Risk : In pinions containing the defect, the fracture of the pinion shaft is expected to
Part 573 Safety Recall Report 22E-027 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Description of the Safety Risk : occur predominantly during a vehicle start-up at low speed (<10 mph) when
the maximum slip aligns with the maximum torque. The fracture location of
the pinion shaft occurs just over one inch from the thread end of the drive
pinion splines.In vehicles with susceptible air brake hose routings, a fractured
pinion may allow for axial separation of the fractured portion of the pinion
shaft and yoke which can allow them to hit the brake drop hose, causing the
hose to rupture. If this occurred, it would unintentionally apply the parking
brakes without the brake lights coming on, possibly resulting in a crash.
Description of the Cause : Meritor’s working theory is that the fracture in the drive pinion spline is
initiated during manufacturing in the straightening or bearing preload yoking
process. Meritor is currently not using the straightening process and Meritor is
currently conducting eddy current in-process inspection after the bearing
preload yoking process in addition to ultrasonic inspection at final for
containment as Meritor’s investigation continues.
Identification of Any Warning
that can Occur :
If the pinion fractures, the driver may hear an audible noise and feel the vehicle
slowing down due to loss of propulsion from the drive axle.
Involved Components :
Component Name : 180 Series Axle Carriers and Gear Sets
Component Description : Pinion
Component Part Number : 5-66167_02
Supplier Identification :
Component Manufacturer
Name : NR
Address : NR
NR
Country : NR
Chronology :
See attached word document titled “Chronology”
Part 573 Safety Recall Report 22E-027 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Meritor will work with the customer and an appropriate repair facility to
determine if the vehicle is affected. If repair is needed, the Differential
Carrier Assembly will be replaced. Gear Sets that were sold separately and
that have not yet been installed into a Differential Carrier Assembly will be
replaced with a new Gear Set. The replacement will be done at no charge
to the customer.
How Remedy Component Differs
from Recalled Component :
The remedied component will meet Meritor’s straightness specifications
without having been subject to the straightening process, which is no
longer used. The remedied component will pass both eddy current and
ultrasonic inspection.
Identify How/When Recall Condition
was Corrected in Production :
On April 20, 2021, Meritor implemented ultrasonic testing at final
inspection. Meritor eliminated the straightening process on February 18,
2022. On March 3, 2022, Meritor validated new design dummy yokes on
the assembly line and began 100% testing of the pinions with both an eddy
current in-process inspection and an ultrasonic inspection at final.
Recall Schedule :
Description of Recall Schedule : Owners notifications will be sent to aftermarket customers affected by
the suspect population.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : MAY 02, 2022 – MAY 13, 2022
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR
Address : NR
NR
Country : NR
Company Phone : NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-027
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Meritor, Inc.
Submission Date : APR 25, 2022
NHTSA Recall No. : 22E-027
Manufacturer Recall No. : NR
Manufacturer Information :
Manufacturer Name : Meritor, Inc.
Address : 2135 West Maple Road
Troy MI 48084
Company phone : 248-435-1725
Population :
Number of potentially involved : 536
Estimated percentage with defect : 1 %
Equipment Information :
Brand / Trade 1 : Meritor
Model : Drive Pinion 180 Series
Part No. : 180 Drive Pinion
Size : NR
Function : Transmit Torque
Descriptive Information : Some 180 Series Drive Pinions with low mileage (below 33,954 miles in linehaul
vehicles and below 8,496 miles in non-linehaul vehicles) may fracture in the
spline. The production date range of the suspect pinions is June 30, 2020
through March 3, 2022. The recalled population does not differ from products
built prior to June 30, 2020. However, Meritor believes that products built prior
to that date would have already failed if they had the defect. Products
manufactured after March 3, 2022 have had both a manufacturing and an
inspection process change. On February 18, 2022, Meritor changed its
production process to eliminate the straightening of pinion shafts. Shafts that do
not meet the specifications for straightness are not straightened or used. On
March 3, 2022, Meritor validated new design dummy yokes on the assembly line
and began 100% testing of the pinions with both an eddy current in-process
inspection and an ultrasonic inspection at final. This 573 Safety Defect Report is
specific to product shipped to Meritor’s aftermarket customers only.
Production Dates : JUN 30, 2020 – MAR 03, 2022
Description of Defect :
Description of the Defect : 180 Series Drive Pinion fractured in the spline
FMVSS 1 : NR
FMVSS 2 : NR
Description of the Safety Risk : In pinions containing the defect, the fracture of the pinion shaft is expected to
Part 573 Safety Recall Report 22E-027 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
Description of the Safety Risk : occur predominantly during a vehicle start-up at low speed (<10 mph) when
the maximum slip aligns with the maximum torque. The fracture location of
the pinion shaft occurs just over one inch from the thread end of the drive
pinion splines.In vehicles with susceptible air brake hose routings, a fractured
pinion may allow for axial separation of the fractured portion of the pinion
shaft and yoke which can allow them to hit the brake drop hose, causing the
hose to rupture. If this occurred, it would unintentionally apply the parking
brakes without the brake lights coming on, possibly resulting in a crash.
Description of the Cause : Meritor’s working theory is that the fracture in the drive pinion spline is
initiated during manufacturing in the straightening or bearing preload yoking
process. Meritor is currently not using the straightening process and Meritor is
currently conducting eddy current in-process inspection after the bearing
preload yoking process in addition to ultrasonic inspection at final for
containment as Meritor’s investigation continues.
Identification of Any Warning
that can Occur :
If the pinion fractures, the driver may hear an audible noise and feel the vehicle
slowing down due to loss of propulsion from the drive axle.
Involved Components :
Component Name : 180 Series Axle Carriers and Gear Sets
Component Description : Pinion
Component Part Number : 5-66167_02
Supplier Identification :
Component Manufacturer
Name : NR
Address : NR
NR
Country : NR
Chronology :
See attached word document titled “Chronology”
Part 573 Safety Recall Report 22E-027 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Description of Remedy :
Description of Remedy Program : Meritor will work with the customer and an appropriate repair facility to
determine if the vehicle is affected. If repair is needed, the Differential
Carrier Assembly will be replaced. Gear Sets that were sold separately and
that have not yet been installed into a Differential Carrier Assembly will be
replaced with a new Gear Set. The replacement will be done at no charge
to the customer. Although Meritor believes all the customers that have
experienced the problem have been covered by our warranty, Meritor will
state in the §577 letter that if the customer has experienced the condition
and it was not covered under warranty, Meritor will reimburse the
customer for parts and labor connected with the replacement of the 180
Series pinion assembly.
How Remedy Component Differs
from Recalled Component :
The remedied component will meet Meritor’s straightness specifications
without having been subject to the straightening process, which is no
longer used. The remedied component will pass both eddy current and
ultrasonic inspection.
Identify How/When Recall Condition
was Corrected in Production :
On April 20, 2021, Meritor implemented ultrasonic testing at final
inspection. Meritor eliminated the straightening process on February 18,
2022. On March 3, 2022, Meritor validated new design dummy yokes on
the assembly line and began 100% testing of the pinions with both an eddy
current in-process inspection and an ultrasonic inspection at final.
Recall Schedule :
Description of Recall Schedule : Owners notifications will be sent to aftermarket customers affected by
the suspect population.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : MAY 02, 2022 – MAY 13, 2022
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : NR
Address : NR
NR
Country : NR
Company Phone : NR
* NR – Not Reported

SEOCONTENT-END