Copyright Meritor, Inc., 2022
MM-0861 / Revised 06-22
Page 48
Printed in USA
5 Disassembly
NOTE:
The high- and low-range clutch collar becomes
loose on the shift fork as the input bearing cage and pump
assembly is removed and may drop into the case. Shifting
the transfer case into high range keeps the shift collar on the
high-range gear, which keeps it in place. Also, shifting into
high range allows easier rear cover removal on the MTC-4208
and MTC-4210 transfer cases.
5. Shift the transfer case into high range using compressed air
at the high-range port of the shift cylinder. Figure 5.15.
Figure 4.15
4000191c
HIGH RANGE
PORT
LOW RANGE
PORT
BLOW-BY
BREATHER
(IF EQUIPPED)
REAR
VIEW
NEUTRAL PORT
(PTO-EQUIPPED ONLY)
Figure 5.15
CAUTION
Use a pry bar and mallet to remove the input cage cover. Take
care not to damage the shim pack. Damage to the transfer case
will result.
6. Use a pry bar and mallet to loosen the input cage cover and
internal pump assembly, if equipped. Figure 5.16.
4006310c
Figure 5.16
7. Remove the shim pack. Figure 5.16.
8. With the front input yoke still installed, remove the yoke nut,
yoke, and front input bearing cage from the assembly.
Figure 5.17.
4018585a
FRONT
VIEW
Figure 5.17
High/Low Shift Cylinder Components
Use the following procedure to disassemble the high/low shift
components before separating the case halves.
1. Rotate the transfer case so the shift cylinder is facing UP.
NOTE:
After the air source is removed, the high range gear
may move out of position.
2. Disconnect the air lines used to shift in the previous steps.
4007106a
NEUTRAL PORT
(MTC-4208 AND
MTC-4210 ONLY)
HIGH RANGE
PORT
LOW
RANGE
PORT
Figure 5.18
3. Remove the high and low range shift cylinder from the rear
cover of the transfer case.
4. Remove the outer shift piston snap ring from the shift shaft.
Remove the shift piston. Figure 5.19.
