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Meritor MM-0861, Maintenance Manual

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Meritor MM-0861 Maintenance Manual Download Page 64

Copyright Meritor, Inc., 2022

MM-0861  /  Revised 06-22
Page 62

Printed in USA

7     Assembly

Assemble the Double Idler Gear Subassembly 
(All Models)

1.  Install the shaft assembly into a press and support it correctly.

2.  Place the bearing cone onto the end of the shaft assembly 

with the appropriate end facing UP. Use a sleeve, (non-XLEV/
XLEC models use "Bearing Cone Driver (905473-82)" on 
page 111) (XLEV/XLEC models use "Bearing Driver (4FI20-
27110-000008-D01)" on page 110), and press to push the 
bearing cone DOWN until it is fully seated. Only press on the 
inner race of the bearing cone. Use a 0.002” shim or feeler 
gauge to ensure the bearing cone is correctly seated.

3.  Turn the shaft assembly over and install the bearing cone on 

the other end using Steps 1-2.

Assemble the Input Shaft Subassembly  
(MTC-4213X Only)

1.  Press the bearing cup into the input bearing cage until it is 

fully seated.

2.  Place the large o-ring around the groove on the bearing cage.

3.  Install the relief valve and spring into the oil pump. The 

plunger should be seated into the relief valve orifice.

4.  Install the internal oil pump using the following procedure.

a. Pack lithium-complex grease, Meritor specification O-668, 

into the pump oil inlet port before assembling the oil pump to 
the input bearing cage.

b. Place the bearing cone on the race in the bearing cage.
c. Insert the relief valve and spring into the relief port of the 

input bearing cage. Install the large diameter end of the spring 
down. Align the oil pump inlet with the oil inlet port of the 
input bearing cage.

d. Install the six pump-to-inlet bearing cage capscrews and 

washers. Apply Loctite

®

 277 sealant to the capscrews. Tighten 

the capscrews to 35-50 lb-ft (48-68 Nm).

e. Lubricate the sealing rings on the inside diameter of the pump 

and the shaft journal adjacent to the pump splines.

5.  Place the small helical gear over the input shaft with the 

spline side of the gear down and install the spiral snap ring. 
The gear is a slip fit.

6.  Install the shaft assembly into a press and support it correctly.

7.  Place the bearing cone onto the end of the shaft assembly 

with the appropriate end facing UP. Use a sleeve, "Bearing 
Cone Driver (905473-82)" on page 111, and press to push 
the bearing cone DOWN until it is fully seated. Only press 
on the inner race of the bearing cone. Use a 0.002” shim or 
feeler gauge to ensure the bearing cone is correctly seated.

8.  Apply Loctite

®

 592 threadlocker to the restrictor plug and 

install it into the end of the bearing cone. Tighten the plug to 
15 lb-ft (20 Nm). Figure 7.6.

4007182a

RESTRICTOR

PLUG

BEARING 

CONE

Figure 7.6 

Assemble the Front Input Shaft, Input Shaft Bearing 
Cage, and Internal Oil Pump Sub-Assemblies  
(MTC-4208X/XP/XL/XLEV/XLEC and MTC-4210X/XP/
XL/XLEV/XLEC Only, If Equipped)

1.  Use "Bearing Cup Driver (910203-37)" on page 113 to 

press the bearing cup into the input bearing cage until it is 
fully seated.

2.  Place the large o-ring around the groove on the bearing cage. 

Figure 7.7.

MTC-4208/4210X AND XP SHOWN 
NOT APPLICABLE TO MTC-4208/4210XL and XLEV

RELIEF VALVE

AND SPRING

4000211b

LARGE

O-RING

Figure 7.7 

3.  Install the internal oil pump, if equipped, using the following 

procedure.

a.

 MTC-4208X/XP and MTC-4210X/XP transfer cases only: 

 

Pack lithium-complex grease, Meritor specification O-668, 
into the pump oil inlet port before assembling the oil pump to 
the input bearing cage. Figure 7.8.

Summary of Contents for MM-0861

Page 1: ...MTC 4208X XL XP XLEV XLEC MTC 4210X XL XP XLEV XLEC AND MTC 4213X SERIES TRANSFER CASES MAINTENANCE MANUAL MM 0861 ...

Page 2: ... are no changes to the oil cooler interface points with these models For more information on MTC 4208 MTC 4210 and MTC 4213GS Series transfer cases refer to Maintenance Manual MM 0146 Transfer Cases To obtain this publication visit Literature on Demand at meritor com How to Obtain Additional Maintenance and Service Information Visit Literature on Demand at meritor com to access and order additiona...

Page 3: ...lity 2 How to Obtain Additional Maintenance and Service Information 2 If Parts Tools and Supplies are Specified in this Manual 2 Section 1 Safety Information 3 Hazard Alert Messages 3 Safety Precautions 3 Section 2 Exploded Views 4 MTC 4208X XP Transfer Case Rear Cover 4 MTC 4208X XP Transfer Case Front Cover 6 MTC 4208XL Transfer Case Rear Cover 8 MTC 4208XL Transfer Case Front Cover 10 MTC 4208X...

Page 4: ... the PTO Assembly Installed 85 PTO Disassembly 85 PTO Assembly 85 Section 9 Installation 88 Install the Transfer Case 88 Oil Cooler Line Connections 88 Section 10 Troubleshooting 91 Transfer Case Lubrication Diagnostics 91 Excessive Noise and Vibration Diagnostics 93 PTO Does Not Engage Disengage Diagnostics 94 Front Axle Declutch Does Not Engage Disengage Diagnostics 95 High Low Gear Shifting Dia...

Page 5: ...llow all safety guidelines and instructions provided by the tool manufacturer Failure to do so can result in death or serious injury and damage to components Park the vehicle on a level surface Block the wheels to prevent the vehicle from moving Support the vehicle with safety stands NEVER work under a vehicle supported only by jacks Jacks can slip and fall over Failure to use safety stands can re...

Page 6: ...Inc 2022 MM 0861 Revised 06 22 Page 4 Printed in USA 2 Exploded Views Exploded Views MTC 4208X XP Transfer Case Rear Cover 4007388a 1 21 6 8 9 10 6 12 13 15 14 15 1 16 25 13 19 20 3 2 4 1 18 17 1 5 3 22 24 23 7 26 27 11 ...

Page 7: ...ng 27 Blow by Breather Item Description 1 Capscrew and Washer 2 Cover 3 Lock Nut 4 Hardened Washer 5 Transfer Case Rear Cover 6 Shipping Protector 7 Shift Cylinder 8 Shift Piston O ring 9 Shift Piston 10 O ring 11 Neutral Breather 12 Speed Sensor 13 Bearing Cup 14 Idler Gear Vehicles not equipped with a transfer case neutral air control may be equipped with a neutral breather which allows the shif...

Page 8: ...Printed in USA 2 Exploded Views MTC 4208X XP Transfer Case Front Cover 4007389a 1 2 3 4 10 9 12 13 14 15 16 28 29 23 24 26 27 31 11 15 6 2 42 39 41 8 7 52 51 50 53 25 30 22 32 33 19 20 5 18 17 40 21 22 FRONT 39 47 48 48 49 28 29 34 35 36 37 38 12 44 43 46 45 ...

Page 9: ...r Male Connector 20 Loop Tube 21 Oil Pump Capscrew and Washer 22 Male Fitting 23 Oil Pump Assembly 24 Bearing Cone 25 Shim 26 Input Bearing Cage 27 Bearing Cage Capscrew and Washer Item Description 28 Lock Nut 29 Flat Washer 30 Input Yoke 31 Input Oil Seal 32 Inlet Oil Tube Assembly 33 Oil Fitting Assembly 34 Front Output Yoke 35 Front Output Oil Seal 36 Switch Assembly 37 Relief Valve Spring 38 R...

Page 10: ...c 2022 MM 0861 Revised 06 22 Page 8 Printed in USA 2 Exploded Views MTC 4208XL Transfer Case Rear Cover 24 20 19 17 18 16 21 22 23 21 33 4 2 34A 33A 34 3 7 8 9 10 12 13 14 6 5 4 1 2 4007101a 32 31 30 29 27 4 11 28 15 25 26 ...

Page 11: ...n O ring 13 Shift Piston 14 O ring 15 Blow by Breather 16 Neutral Breather 17 Shipping Protector 18 Neutral Breather Fitting Item Description 19 Speed Sensor 20 Capscrew and Washer 21 Bearing Cups 22 Bearing Cone 23 Double Idler Gear 24 Rear Housing 25 Breather 26 Elbow 27 Filter Screen Assembly Tube 28 O ring Housing 29 Rear Output Oil Seal 30 Rear Output Yoke 31 Flat Washer 32 Lock Nut 33 Oil Pu...

Page 12: ...rinted in USA 2 Exploded Views MTC 4208XL Transfer Case Front Cover 4007102a 11 14 19 29 30 32 31 36 44 51 25 26 28 27 50 24 30 29 22 39 42 23 17 18 38 42 43 42 41 38 42 40 45 46 47 42 36 35 9 8 2 1 39 12 10 13 39 3 4 5 6 7 38 20 20 16 15 21 48 37 49 34 33 35 ...

Page 13: ...ront Cover Housing 19 Plug 20 Locating Dowel Pin 21 Elbow 22 Oil Spacer 23 Shim 24 O ring 25 Input Bearing Cage Item Description 26 Bearing Cage Capscrew and Washer 27 Input Oil Seal 28 Input Yoke 29 Flat Washer 30 Lock Nut 31 Front Output Yoke 32 Front Output Oil Seal 33 Plug Fitting 34 Declutch Cylinder 35 O ring 36 Declutch Cylinder Piston 37 Drain Plug 38 Shim 39 Bearing Cup 40 Front Output Cl...

Page 14: ...s MTC 4208XLEV XLEC Transfer Case Rear Cover 32 35 36 33 39 34 38 24 19 18 16 17 15 20 20 21 21 21 22 23 22 20 20 30 4 31 WITHOUT OIL COOLER 30A 31 2 6 7 8 10 9 12 13 5 4 3 4011708c 29 28 27 26 25 3 11 14 1 1A XLECVARIANT 37A 37B 40 41 42 43 OR If installing an EC kit on an EV see TP 1923 ...

Page 15: ...g 18 Speed Sensor 19 Capscrew and Washer 20 Bearing Cups 21 Shims 22 Bearing Cone 23 Double Idler Gear Item Description 24 Rear Housing 25 Filter Screen Tube Assembly 26 Rear Output Oil Seal 27 Rear Output Yoke 28 Flat Washer 29 Lock Nut 30 Oil Pump Inlet Tube 30A Tube Assembly without Oil Cooler 31 Fitting without Oil Cooler 32 Pump Cover Assembly 33 6 Male JIC 37 x 3 8 NPT Fitting 34 Connector F...

Page 16: ...ed in USA 2 Exploded Views MTC 4208XLEV XLEC Transfer Case Front Cover 20 49 50 53 52 51 20 55 54 43 41 20 42 45 20 48 49 50 47 46 9 43 44 2 1 4 3 5 6 8 7 9 10 11 12 13 14 39 57 40 34 17 56 35 37 36 38 31 32 33 30 31 30 29 28 25 27 23 24 22 21 20 19 26 15 16 18 17 ...

Page 17: ...24 O ring 25 Input Bearing Cage 26 Bearing Cage Capscrew and Washer 27 Input Oil Seal 28 Yoke Sleeve 29 Input Yoke Item Description 30 Flat Washer 31 Lock Nut 32 Front Output Yoke 33 Front Output Oil Seal 34 Elbow 35 Plug Fitting 36 Declutch Cylinder 37 O ring 38 Declutch Cylinder Piston 39 Fill Plug Adapter 40 Drain Plug 41 Magnets 42 Push Rod 43 Bearing Cup 44 Driven Gear and Rear Output Shaft 4...

Page 18: ... Meritor Inc 2022 MM 0861 Revised 06 22 Page 16 Printed in USA 2 Exploded Views MTC 4210X XP Transfer Case Rear Cover 17 4007388a 2 1 7 10 11 12 7 16 17 19 18 2 20 26 27 5 3 4 2 25 24 2 6 21 5 23 22 9 8 15 14 13 ...

Page 19: ... ring 13 Blow by Breather 14 Housing O ring Vehicles not equipped with a transfer case neutral air control may be equipped with a neutral breather which allows the shift cavity to exhaust On vehicles equipped with a neutral air control the solenoid allows this cavity to exhaust Item Description 15 Neutral Breather 16 Speed Sensor 17 Bearing Cup 18 Bearing Cone 19 Idler Gear 20 Ceramic Magnet 21 Sh...

Page 20: ...18 Printed in USA 2 Exploded Views MTC 4210X XP Transfer Case Front Cover 4007389a 1 2 3 4 44 11 41 9 8 11 12 13 14 15 26 27 26 27 32 33 34 22 2 24 25 29 42 10 2 40 37 39 7 23 28 21 30 31 18 19 5 17 16 43 38 20 35 36 21 FRONT 37 45 46 46 47 2 6 50 48 49 8 ...

Page 21: ...Oil Cooler Male Connector 19 Loop Tube 20 Oil Pump Capscrew and Washer 21 Male Fitting 22 Oil Pump Assembly 23 Shim 24 Input Bearing Cage 25 Bearing Cage Capscrew and Washer 26 Lock Nut Item Description 27 Flat Washer 28 Input Yoke 29 Input Oil Seal 30 Inlet Oil Tube Assembly 31 Oil Fitting Assembly 32 Front Output Yoke 33 Front Output Oil Seal 34 Switch Assembly 35 Relief Valve Spring 36 Relief V...

Page 22: ...2022 MM 0861 Revised 06 22 Page 20 Printed in USA 2 Exploded Views MTC 4210XL Transfer Case Rear Cover 24 20 19 17 18 16 21 22 23 22 21 33 4 2 34A 33A 34 3 7 8 9 10 12 13 14 6 5 4 1 2 4007101a 32 31 30 29 27 4 11 28 15 25 26 ...

Page 23: ...on O ring 13 Shift Piston 14 O ring 15 Blow by Breather 16 Neutral Breather 17 Shipping Protector 18 Neutral Breather Fitting Item Description 19 Speed Sensor 20 Capscrew and Washer 21 Bearing Cup 22 Bearing Cone 23 Double Idler Gear 24 Rear Housing 25 Breather 26 Elbow 27 Filter Screen Assembly Tube 28 Housing O ring 29 Rear Output Oil Seal 30 Rear Output Yoke 31 Flat Washer 32 Lock Nut 33 Oil Pu...

Page 24: ...rinted in USA 2 Exploded Views MTC 4210XL Transfer Case Front Cover 4007102a 7 9 15 27 28 30 31 29 32 33 34 37 35 22 23 26 24 25 21 28 27 18 19 17 20 13 14 12 17 36 17 45 12 17 46 44 43 42 17 40 41 39 17 40 41 19 38 6 8 19 1 2 3 4 5 12 16 16 11 10 50 49 47 48 ...

Page 25: ...ng Cup 20 Shim 21 O ring 22 Input Bearing Cage 23 Bearing Cage Capscrew and Washer 24 Input Oil Seal 25 Yoke Sleeve Item Description 26 Input Yoke 27 Flat Washer 28 Lock Nut 29 Front Output Yoke 30 Front Output Oil Seal 31 Plug Fitting 32 Declutch Cylinder 33 O ring 34 Declutch Cylinder Piston 35 Push Rod 36 Driven Gear and Rear Output Shaft 37 Spring 38 High and Low Clutch Collar 39 Helical Drive...

Page 26: ... MTC 4210XLEV XLEC Transfer Case Rear Cover 32 35 36 33 39 34 38 24 19 18 16 17 15 20 20 21 21 21 22 23 22 20 20 30 4 31 WITHOUT OIL COOLER 30A 31 2 6 7 8 10 9 12 13 5 4 3 4011708c 29 28 27 26 25 3 11 14 1 1A XLEC VARIANT 37A 37B 40 41 42 43 OR If installing an EC kit on an EV see TP 1923 ...

Page 27: ...g 18 Speed Sensor 19 Capscrew and Washer 20 Bearing Cups 21 Shims 22 Bearing Cone 23 Double Idler Gear Item Description 24 Rear Housing 25 Filter Screen Assembly Tube 26 Rear Output Oil Seal 27 Rear Output Yoke 28 Flat Washer 29 Lock Nut 30 Oil Pump Inlet Tube 30A Tube Assembly without Oil Cooler 31 Fitting without Oil Cooler 32 Pump Cover Assembly 33 6 Male JIC 37 x 3 8 NPT Fitting 34 Connector F...

Page 28: ... USA 2 Exploded Views MTC 4210XLEV XLEC Transfer Case Front Cover 4011709b 7 10 17 30 31 33 35 32 36 37 38 44 42 25 26 29 27 24 31 30 21 20 23 15 16 43 20 45 20 54 20 55 53 52 51 20 49 50 47 48 49 50 43 46 9 8 9 4 43 1 2 3 5 6 19 13 14 12 11 18 22 41 34 17 39 40 56 28 ...

Page 29: ...Cup 23 Shim 24 O ring 25 Input Bearing Cage 26 Bearing Cage Capscrew and Washer 27 Input Oil Seal 28 Yoke Sleeve Item Description 29 Input Yoke 30 Flat Washer 31 Lock Nut 32 Front Output Yoke 33 Front Output Oil Seal 34 Elbow 35 Plug Fitting 36 Declutch Cylinder 37 O ring 38 Declutch Cylinder Piston 39 Fill Plug 40 Drain Plug 41 Magnets 42 Push Rod 43 Bearing Cup 44 Spring 45 Driven Gear and Rear ...

Page 30: ...61 Revised 06 22 Page 28 Printed in USA 2 Exploded Views MTC 4213X Transfer Case Rear Cover 9 8 5 11 12 13 13A 15 16 14 38 17 21 23 24 29 28 30 7 31 32 23 27 25 40 41 36 35 34 33 37 21 23 4 3 2 1 18 21 19 20 22 7 6 4007103a 26 39 10 7 ...

Page 31: ... 14 Neutral Breather 15 Neutral Breather Fitting 16 Plug 17 Speed Sensor 18 Capscrew 19 Washer 20 O ring Item Description 21 Bearing Cup 22 High and Low Shift Shaft 23 Bearing Cone 24 Rear Output Shaft 25 Plug 26 Pocket Bearing 27 Helical Drive Gear High Range 28 Shift Fork Capscrew 29 High and Low Shift Fork 30 High and Low Clutch Collar 31 Helical Drive Gear Low Range 32 Input Shaft 33 Shims 34 ...

Page 32: ...0861 Revised 06 22 Page 30 Printed in USA 2 Exploded Views MTC 4213X Transfer Case Front Cover 3 26 3 1 1 25 27 28 3 1 29 30 31 1 15 16 1 2 1 4 6 23 7 16 15 18 19 7 24 22 21 17 20 16 15 14 12 13 8 4007104a 5 11 10 9 FRONT 7 32 32 33 ...

Page 33: ...10 Front Oil Pump 11 O ring 12 Input Bearing Cage 13 Input Oil Seal 14 Input Yoke 15 Flat Washer 16 Lock Nut 17 Plug Item Description 18 Front Output Yoke 19 Front Output Oil Seal 20 Declutch Shift Cylinder 21 Shift Piston O ring 22 Declutch Shift Piston 23 Shift Piston O ring 24 Inlet Tube 25 Single Idler Gear 26 Shift Fork Spring 27 Shift Fork 28 Shift Shaft 29 Front Output Shaft 30 Helical Driv...

Page 34: ...Copyright Meritor Inc 2022 MM 0861 Revised 06 22 Page 32 Printed in USA 2 Exploded Views MTC 4208XP and MTC 4210XP Declutch PTO 4000182a 4 3 2 18 19 5 6 7 8 14 15 16 2 13 12 11 10 9 17 1 ...

Page 35: ... Switch Assembly Engage 2 Capscrew 3 Cap 4 Shifter Spring 5 Flat Washer 6 Special Screw 7 Connector Switch Assembly Disengage Optional 8 Shipping Protector 9 Push Rod 10 Shifter Piston 11 O ring 12 O ring 13 Cover Plate 14 Clutch Collar 15 Shift Fork 16 Bearing Assembly 17 PTO Housing 18 PTO Shaft 19 Oil Seal Assembly ...

Page 36: ...Range by 1 000 lb ft Optional Features Not Included as Standard Equipment up to three characters High Ratio Transfer Case Housing Material Low Ratio CV Common Variant EC Enhanced Cooling EV Evolution Reduced Temperature FV Factory Variant GV Governing Variant Number of Speeds 1 Single Speed 2 Two Speed G Grey Iron D Ductile Iron A Aluminum X Increased Sump Capacity 1 Single Speed Design 2 Two Spee...

Page 37: ...instrument panel engages or disengages a mechanical clutch An optional speed sensor measures transfer case output driveline rpm Optional switches indicate when the front axle declutch is fully engaged or disengaged These transfer cases provide for two speed output high range and low range and a neutral position used for PTO equipped transfer cases only Non PTO cases can have this neutral position ...

Page 38: ...TC 4210XL HIGH RANGE GEAR EXTERNAL OIL PUMP REAR OUTPUT SHAFT LOW RANGE GEAR DOUBLE IDLER GEAR INPUT SHAFT FRONT OUTPUT SHAFT Figure 3 5 4011713a MTC 4208XLEV and MTC 4210XLEV HIGH RANGE GEAR EXTERNAL OIL PUMP REAR OUTPUT SHAFT LOW RANGE GEAR DOUBLE IDLER GEAR NEEDLE BEARING INPUT SHAFT FRONT OUTPUT SHAFT NEEDLE BEARING Figure 3 6 4000184c MTC 4208XP and MTC 4210XP AIR CONTROL PORT SWITCH CONNECTO...

Page 39: ...Shift the transfer case into low from high gear or from high to low gear when the vehicle is stationary Apply the parking brake with the transmission in Neutral on automatic or manual transmissions If the clutch does not fully engage Turn the steering wheel in one direction and rock the vehicle back and forth until engagement occurs Engagement can be confirmed by hearing it noticing improved vehic...

Page 40: ...SSOVER TUBE CONNECTION PUMP INLET CONNECTION OIL PUMP OUTLET TO COOLER MTC 4208 10 XLEC VARIANT PUMP COVER 4014941d OR Figure 3 10 Figure 2 10 MTC 4208XLEV and MTC 4210XLEV INLET TUBE FITTING INLET TUBE PUMP COVER REAR FRONT BREATHER ELBOWW ORIFICE PLUG RETURN FROM COOLER DRAIN PLUG MAGNETIC PLUG OIL PUMP OUTLET TO COOLER 4012334a Figure 3 11 OIL PUMP CROSSOVER TUBE TEE FITTING OE COOLER LINE CONN...

Page 41: ... RANGE PORT LOW RANGE PORT BLOW BY BREATHER IF EQUIPPED NEUTRAL PORT PTO EQUIPPED ONLY Figure 3 14 Full Torque Power Take Off PTO CAUTION Do not engage the full torque power take off PTO when the transfer case prop shafts are turning Damage to the transfer case will result Engage or disengage the PTO when the vehicle is stationary the transmission is in Neutral and the transfer case prop shafts ar...

Page 42: ...rectives can result in death or serious personal injury and damage to components WARNING To prevent eye injury always wear eye protection when performing vehicle maintenance or service Remove the Transfer Case Assembly 1 Wear eye protection 2 Park the vehicle on a level surface Place blocks under the wheels not being raised to keep the vehicle from moving 3 Raise the vehicle so the area to be serv...

Page 43: ...ROSSOVER TUBE TEE FITTING OE COOLER LINE CONNECTION 4016827b P CLAMP ASSEMBLY MTC 4208 10 XLEC DRIVER SIDE MOUNTED COOLER Figure 4 5 OIL PUMP CROSSOVER TUBE 4016829b P CLAMP ASSEMBLY MTC 4208 10 XLEC PASSENGER SIDE MOUNTED COOLER Figure 4 6 8 Disconnect the air lines at the shift cylinders of the transfer case 9 Disconnect the harness for the indicator switch wires 10 Use a hydraulic roller jack t...

Page 44: ...se housing Lifting holes are located at the top and bottom of each half of the transfer case near the center Figure 4 9 4000188a LIFTING HOLE LIFTING HOLE REAR COVER LIFTING HOLE FRONT COVER LIFTING HOLE Figure 4 9 DANGER Support the transfer case with a lifting strap before mounting the transfer case into the repair stand A transfer case not supported correctly can fall Death or serious personal ...

Page 45: ...e oil lines and cap the oil cover fittings d Remove the external oil pump housing from the transfer case e Remove the oil pump assembly from the rear of the input shaft Refer to the procedure on page 45 2 MTC 4208X and MTC 4210X Transfer Cases Only a Disconnect the transfer case oil inlet line from the oil pump cover Figure 5 2 MTC 4208X XP MTC 4210X XP AND MTC 4213X 4006988a WITH INTERNAL OIL PUM...

Page 46: ...aft assembly from the transfer case If necessary use a yoke puller or an appropriate lifting device It may be necessary to gently pry the input bearing cage up to dislodge it from the transfer case 6 Remove the shims NOTE The MTC 4213X has a two piece through shaft Because of this design only the forward half of the input shaft will be removed while the upper rear output shaft will remain in place...

Page 47: ...ET TUBE FITTING INLET TUBE PUMP COVER REAR FRONT ELBOWW ORIFICE PLUG RETURN FROM COOLER DRAIN PLUG MAGNETIC PLUG OIL PUMP OUTLET TO COOLER 4007121a Figure 5 5 Figure 2 10 MTC 4208XLEV and MTC 4210XLEV INLET TUBE FITTING INLET TUBE PUMP COVER REAR FRONT BREATHER ELBOWW ORIFICE PLUG RETURN FROM COOLER DRAIN PLUG MAGNETIC PLUG OIL PUMP OUTLET TO COOLER 4012334a Figure 5 6 OIL PUMP CROSSOVER TUBE CONN...

Page 48: ...ins located on the rear half on the input shaft Figure 5 11 4007115a PUMP PIN SLOT DRIVE PIN INPUT SHAFT DRIVE PIN MTC 4208XL XLEV XLEC AND MTC 4210XL XLEV XLEC Figure 5 11 4 If necessary disassemble the pump as follows a Remove the spring from the rear half of the input shaft b Gently tap the idler carrier out of the rotor The idler and floating plate will come out with the idler carrier Figure 5...

Page 49: ...ut and washer from the rear half of the input shaft Use a yoke tool on the input shaft yoke to prevent the shaft from rotating while removing the retaining nut If the input shaft retaining nut cannot be removed it will not be possible to remove the front input shaft before opening the housing Skip this procedure NOTE The MTC 4213X has a split shaft design It is only necessary to remove the front h...

Page 50: ...im 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 Com...

Page 51: ...d If they are not marked with the lift capacity do not use them Inspect lifting straps to ensure they are not damaged NEVER subject lifting straps to shocks or drop loading Failure to follow these directives can result in death or serious personal injury and damage to components CAUTION As the rear cover is lifted apply DOWNWARD pressure on the shift rod to prevent the gears from dropping out of t...

Page 52: ... rear nut Support the shaft correctly 2 Remove the rear nut and washer 3 Remove the yoke 4 Prepare the shaft for bearing and gear removal Install the front output shaft into a press with the rear of the output shaft facing UP Support the shaft correctly Figure 5 24 PRESS SHAFT BLOCK 4007098b Figure 5 24 5 Press the shaft DOWNWARD to remove the rear tapered roller bearing helical gear clutch collar...

Page 53: ...do not mix with other bearings 5 Remove the high range helical gear from the upper rear output shaft The gear is splined to the shaft 6 Turn the shaft assembly over Install a bearing separator or suitable tool under the bearing 7 Install the shaft assembly into a press 8 Press the shaft assembly DOWNWARD until the bearing is free from the shaft Disassemble the Front Input Shaft Input Shaft Bearing...

Page 54: ...tor is damaged in any way The bearing cup is pressed into the bearing cage d Remove the relief valve and spring 7 Replace the bearing cone and cup as necessary Idler Gear and Rear Output Shaft Disassembly 1 Use a suitable bearing cone puller to remove the bearing cones as necessary from the single idler gear shaft rear output shaft on MTC 4208 and MTC 4210 transfer cases or double idler gear shaft...

Page 55: ...maintenance or service Clean Parts Ground and Polished Parts CAUTION NEVER use hot solution tanks or water and alkaline solutions to clean ground or polished parts Damage to parts can result NEVER clean ground or polished parts in a hot solution tank water steam or alkaline solution to avoid damaging the surfaces Use a cleaning solvent to clean ground or polished parts or surfaces NEVER USE GASOLI...

Page 56: ... It is very important to inspect all parts carefully and completely before the transfer case is assembled Check all parts for wear and stress Replace all damaged parts to avoid costly downtime at a future date For more detailed information about parts inspection refer to TP 0445 Meritor Parts Failure Analysis To obtain this publication refer to the Service Notes page on the front inside cover of t...

Page 57: ...place worn or damaged parts Inspect the rotor housing and idler of the oil pump if equipped for scoring Inspect the drive tab of the rotor assembly Inspect the splines on the pump inner rotor for cracks along the spline area Also check for excessive wear Replace the pump if these conditions exist Remove and inspect the plug at the end of the input shaft Verify the orifice is clear of debris Repair...

Page 58: ... ventilated Read the manufacturer s instructions before using a silicone gasket material then carefully follow the instructions If a silicone gasket material gets into the eyes follow the manufacturer s emergency procedures and get checked by a physician as soon as possible The silicone gasket products listed in the table below or their equivalent can be used on Meritor components Table A Silicone...

Page 59: ...sealants to fasteners with pre applied adhesive or to fastener holes 3 Tighten the fasteners to the required torque value for that size fastener No drying time is required for fasteners with pre applied adhesive Original or Used Fasteners 1 Use a wire brush to clean the oil dirt and old adhesive from all threads and threaded holes 2 Apply liquid adhesive to the bolt threads or bore threads as requ...

Page 60: ...r shift fork and sensors for damage If any of the following conditions exist replace the component Cracks in the housing Cracks along the shaft yoke spline or ball bearing abutment Magnaflux may be necessary to see small cracks Chipped or cracked shifting splines on the shift collar or shaft The rollers of the taper bearings do not roll easily or lack lubrication The raceway is cracked or dented C...

Page 61: ...e if necessary External Rear Mounted Oil Pump 1 Verify the pump drive pins on the rear half of the input shaft correctly engage the pump If necessary remove the pump and reinstall it in the correct position 2 Inspect the pump gear for damage 3 Verify the transfer spring is in good condition 4 Once the transfer case has been installed on the vehicle verify the pump pressure is correct Refer to the ...

Page 62: ...ound from entering bearings oil galleries and passages or tapped holes All beads must be kept smaller than 0 100 diameter Gear and Shaft Sub Assembly Build Up Assemble the Front Output Shaft Subassembly 1 Use an appropriate holding fixture to fully support the shaft assembly Refer to the Holding Fixture 905473 140 on page 108 DANGER Observe all hazard alerts provided by the press manufacturer Deat...

Page 63: ...sher and the locknut onto the shaft Tighten the locknut to 700 900 lb ft 949 1220 Nm Figure 7 5 HOLDING FIXTURE TOOL 905473 140 LOCKNUT 4006927a WASHER Figure 7 5 Assemble the Single Idler Gear Subassembly MTC 4213X Only 1 Install the shaft assembly into a press and support it correctly with the forward end facing UP 2 Place the bearing onto the forward end of the shaft assembly Use a sleeve Beari...

Page 64: ...age capscrews and washers Apply Loctite 277 sealant to the capscrews Tighten the capscrews to 35 50 lb ft 48 68 Nm e Lubricate the sealing rings on the inside diameter of the pump and the shaft journal adjacent to the pump splines 5 Place the small helical gear over the input shaft with the spline side of the gear down and install the spiral snap ring The gear is a slip fit 6 Install the shaft ass...

Page 65: ...P RING OIL SPACER NEEDLE BEARING XLEV XLEC ONLY LOW RANGE HELICAL GEAR INPUT SHAFT Figure 7 10 5 Place the low range helical gear over the input shaft with the spline side of the gear down For MTC 4208XLEV XLEC and MTC 4210XLEV XLEC install the oil spacer The oil spacer has two oil channels cut into it The oil channels can face forward or aft when installed Install the spiral snap ring to secure t...

Page 66: ...river 905473 82 on page 111 Use a 0 002 shim or feeler gauge to verify the bearing is fully seated against the gear Figure 7 13 SLEEVE TOOL 905473 82 4007167a HELICAL GEAR BEARING PRESS Figure 7 13 Gear and Shaft Installation into the Transfer Case Halves Before installing the gear shafts refer to End Play Check and Adjustment on page 67 for the correct shim pack starting thickness 1 Lubricate all...

Page 67: ... pins into the corresponding holes in the front case NOTE Do not install sealant at this time DANGER Follow all safety guidelines and instructions provided by the lifting device manufacturer Check that the lift capacity marked on the lifting device straps and chains is correct for the weight being lifted If they are not marked with the lift capacity do not use them Inspect lifting straps to ensure...

Page 68: ...aring are a slip type fit 7 MTC 4208X XL XP XLEV XLEC and MTC 4210X XL XP XLEV XLEC Models Install the 3 76 mm diameter nut and washer onto the rear end of the input shaft Tighten the nut to 700 900 lb ft 949 1220 Nm 8 After installing all gearing and shaft assemblies into the transfer case half continue the assembly of the transfer case by installing the rear cover Refer to End Play Check and Adj...

Page 69: ...he end play to 0 002 0 004 0 051 0 102 mm After setting the MTC 4213X upper rear output rotate the transfer case and set the input shaft end play to 0 002 0 004 0 051 0 102 mm All other MTC 4213X shaft end plays are 0 001 0 005 0 025 0 127 mm MTC 4208X XP XL XLEV XLEC and MTC 4210X XP XL XLEV XLEC input shaft initial starting shim pack thickness is 0 036 MTC 4208XP and MTC 4210XP upper rear output...

Page 70: ...put shaft several times to seat the bearings 3 Set up a dial indicator to check the output shaft bearing end play Center the dial indicator over the shaft NOTE For accuracy place a ball bearing into the recess found on the end of the shaft then place the tip of the dial indicator on top of the ball bearing Figure 7 23 and Figure 7 24 MTC 4210XLEV XLEC FRONT OUTPUT YOKE SHOWN 4011825a Figure 7 24 4...

Page 71: ... pry bars to lift up on the bolt head to obtain a measurement To obtain a consistent and averaged reading perform this operation two or three times Record the reading for this shaft The specification is 0 002 0 006 0 051 0 152 mm If the end play is greater than 0 006 0 152 mm Add shims to reduce end play If the end play is less than 0 002 0 051 mm Remove shims to increase end play Bearing shims co...

Page 72: ...000213a Figure 7 29 2 Use a pry bar to lift the yoke to obtain a measurement To obtain a consistent and averaged reading perform this operation two or three times Record the reading for the input shaft The specification for MTC 4208 and MTC 4210 transfer cases is 0 002 0 006 0 052 0 152 mm and 0 002 0 004 0 051 0 102 mm for the MTC 4213 transfer case If the end play is greater than 0 006 0 152 mm ...

Page 73: ...10 models shims are installed between the bearing cups and housing bore on the rear cover except at the input shaft position The shims for input shaft are installed between the input cage and front cover On MTC 4213 models the front input shaft is shimmed between the input cage and front case half The rear output shaft is shimmed between the two tapered bearing set All others shafts are shimmed be...

Page 74: ...mm bead of Loctite 277 sealant to the first three threads of the shift cylinder 6 Install the high and low shift cylinder Tighten the cylinder to 80 100 lb ft 108 136 Nm Input Shaft Oil Seal and Yoke For all transfer cases Install the input seal and sleeve using Meritor kits 2728T1 and 2728T2 respectively Install the forward output shaft seal using Meritor Kit 4454 For MTC 4208X XL XP XLEV XLEC an...

Page 75: ...dures NEVER hit steel parts with a steel hammer Pieces of a part can break off Serious personal injury and damage to components can result 5 Apply a light coat of lubricant to the yoke seal journal Position the sleeve into the yoke sleeve driver NEVER touch the greased areas of the sleeve The sleeve must be kept clean prior to assembly into the seal Use an arbor press and the appropriate driver to...

Page 76: ... WASHER YOKE NUT SEALANT Figure 7 38 11 Install the rear output shaft yoke washer and new yoke nut Tighten the nut to 700 900 lb ft 949 1220 Nm Front Axle Shift Cylinder 1 Rotate the transfer case to install the front axle shift cylinder 2 Remove the front axle shift cylinder used to temporarily hold the shift shaft in place 3 Grease the o ring on the piston and install the piston into the cylinde...

Page 77: ...INPUT SHAFT Figure 7 41 2 Install the pump spring into the orifice at the rear of the input shaft 3 Place the pump onto the input shaft Rotate the pump assembly to engage the drive pins Ensure the pump is correctly seated Leave 3 16 4 763 mm of the drive pins extending from the input shaft Figure 7 42 4007115a PUMP PIN SLOT DRIVE PIN INPUT SHAFT DRIVE PIN MTC 4208XL XLEV XLEC AND MTC 4210XL XLEV X...

Page 78: ...must be at this orientation to prevent damage to components Figure 7 45 11 Install the pump cover washers and bolts Figure 7 46 4007118a PUMP HOUSING PUMP COVER WASHER PUMP COVER BOLT MTC 4208XL XLEV XLEC AND MTC 4210XL XLEV XLEC Figure 7 46 12 Use a 7 16 socket and tighten the bolts in a criss cross pattern to 10 13 lb ft 14 18 Nm Breather Speed Sensor and Plugs 1 If necessary install the breathe...

Page 79: ...se Shifting Check 1 Apply 60 psi 4 14 bar or greater of air pressure to the front axle declutch Figure 7 49 2 Turn the input shaft by hand to verify the front output turns at same rate as the rear output 3 Remove the air pressure 4 Apply 60 psi 4 14 bar or greater of air pressure to the high range shaft air port Figure 7 50 MTC 4208XP AND MTC 4210XP SHOWN 4000218c AIR CONTROL PORT NEUTRAL PORT HIG...

Page 80: ...s are installed correctly 3 Remove the breather assembly Figure 7 51 MTC 4208X AND MTC 4210X REAR OUTPUT POSITION PTO LOCATION 4004233a BREATHER REAR COVER Figure 7 51 4 With the correct fitting installed into the breather port apply a pressure of 8 10 psi 0 55 0 69 bar 5 Shut the air supply off If the pressure decreases by more than 2 psi 0 14 bar in 10 minutes Check for external leaks at the fit...

Page 81: ...y procedures and get checked by a physician as soon as possible WARNING Take care when using Loctite adhesive to avoid serious personal injury Read the manufacturer s instructions before using this product Follow the instructions carefully to prevent irritation to the eyes and skin If Loctite adhesive material gets into the eyes follow the manufacturer s emergency procedures and get checked by a p...

Page 82: ... Shaft 1 4 Push Rod 1 5 Shift Fork 1 6 Differential Lockout Collar 1 7 Shifter Piston 1 8 O ring 1 46 37 mm Diameter 1 9 O ring 1 80 46 mm Diameter 1 10 Cover Plate 1 11 Switch Assembly Standard Optional 1 Item Description Qty 12 Capscrew 1 13 Shifter Spring 1 14 Cap 1 15 Declutch Switch Assembly Optional 1 16 Oil Seal Assembly 1 17 Shipping Protector 1 18 Flat Washer 2 19 Special Screw 2 20 Capsc...

Page 83: ...container under the transfer case to catch the hydraulic fluid when removing the rear access cover 4 Remove the mounting bolts and washers securing the rear mounted pump housing Figure 8 2 NOTE It is necessary to replace the rear mounted pump with the internal pump in order to install the PTO Refer to Technical Bulletin TP 0708 Removing the External Oil Pump and Installing the Internal Oil Pump fo...

Page 84: ...ase and KIT 2540 Components 4000219c 10 5 4 3 2 6 7 8 9 1 Figure 8 2 Item Description 1 Transfer Case 2 PTO Assembly 3 Washer 0 47 12 mm Inside Diameter 4 Capscrew 1 25 32 mm Long 5 Capscrew 5 75 146 mm Long 6 Yoke 7 Washer Yoke Mounting 8 Lock Nut Yoke Mounting 9 Switch and Connector Assembly 10 Dowel Pin Kit 2540 component ...

Page 85: ... press and an applied press force of 500 1500 lbs 227 680 kg to install a Meritor yoke spline code RAI onto the PTO shaft Figure 8 2 2 Apply a 1 8 46 mm bead of RTV silicone gasket material around the end of the yoke spline under the washer surface 3 Install the washer and locknut supplied in the kit Tighten the lock nut to 700 900 lb ft 949 1220 Nm Install the Optional Indicator Switch Table F PT...

Page 86: ...ptional Indicator Switch 1 Remove the switch port screw and washer Figure 8 4 2 Measure the PTO push rod travel to verify the travel is 0 75 19 mm and the clutch is fully engaged If the push rod travel is not at 0 75 19 mm and the PTO clutch is not fully engaged Disengage the clutch by releasing the air pressure Rotate the clutch output shaft by hand and retest If the clutch still is not fully eng...

Page 87: ... each bolt a few turns at a time until all the bolts can be removed at once 2 Remove the capscrews from the cover of the declutch piston Remove the cover 3 Remove the PTO piston push rod and the return spring Remove the o ring seal from the PTO piston 4 Remove the o ring seal on the cover Discard the seal Remove the shift fork and clutch collar 5 Remove the oil and dirt seals from the bearing cage...

Page 88: ... install it onto the shaft Figure 8 10 4000224a SPACER BEARING CONE Figure 8 10 e Support the shaft and apply a press of 50 60 lbs 23 27 kg to the bearing cone to set the bearing in place while the bearing cools f Apply a light film of SAE Grade full synthetic 40W or 50W oil Meritor specification O 81 g Assemble the shift fork to the clutch collar Install this unit into the bearing cage housing h ...

Page 89: ...akage by performing the following steps a With the correct fitting installed into the air control port apply a pressure of 90 psi 6 2 bar b Shut off the air supply CAUTION Check for external leaks at the cover plate joint and fitting if the pressure decreases more than 5 psi 0 3 bar in 10 minutes Leaks can cause component damage c Check for external leaks at the cover plate joint and fitting if th...

Page 90: ...r case into the vehicle with the mounting bolts Tighten the bolts to the torque specification supplied by the vehicle manufacturer 4 Connect the drivelines to the input and output yokes of the transfer case Refer to the vehicle manufacturer s recommended procedure 5 Connect any switch or speed sensor wiring 6 Fill the transfer case with the correct quantity of specified lubricant Refer to Lubricat...

Page 91: ... MAGNETIC PLUG OIL PUMP OUTLET TO COOLER 4007121a Figure 9 2 Figure 2 10 MTC 4208XLEV and MTC 4210XLEV INLET TUBE FITTING INLET TUBE PUMP COVER REAR FRONT BREATHER ELBOWW ORIFICE PLUG RETURN FROM COOLER DRAIN PLUG MAGNETIC PLUG OIL PUMP OUTLET TO COOLER 4012334a Figure 9 3 OIL PUMP CROSSOVER TUBE CONNECTION PUMP INLET CONNECTION OIL PUMP OUTLET TO COOLER MTC 4208 10 XLEC VARIANT PUMP COVER 4014941...

Page 92: ... P clamp bracket is intended to support the crossover tube Make certain there is no tension applied to the crossover tube once the fasteners have been tightened MTC 4208 10 XLEC Crossover Hose Installation for Passenger Side Mounted Cooler Connection at 9 00 Position 1 Install the tee fitting onto the front case idler bearing oil supply port elbow fitting Tighten the tee fitting to 20 lb ft 54 Nm ...

Page 93: ...s mounted in the correct location Call the Meritor OnTrac Customer Call Center at 866 OnTrac1 668 7221 for additional information Yes Yes Yes No No No Clean the transfer case and operate the vehicle Inspect the breather for clogging or oil blowing out Inspect the transfer case for housing damage and joint seal leaks 1 Check the transfer case oil level 2 Check the transfer case for air leaks Inspec...

Page 94: ... case requires an oil cooler Call the Meritor OnTrac Customer Call Center at 866 OnTrac1 668 7221 for additional information Check the oil level in the transfer case Too much oil or the incorrect type of oil can cause the transfer case to overheat which may cause seal damage Continued from previous page Road test the vehicle then check for leaks Return vehicle to service Fill the transfer case wit...

Page 95: ... specifications Check all drivelines for adequate balancing Replace or rebalance driveline Check u joints for excessive wear and damaged rollers Check for loose or broken case to vehicle mounting brackets and fasteners Return the vehicle to service Road test the vehicle to determine if noise vibration is still present Replace broken brackets and or tighten all fasteners to specified torque Yes Yes...

Page 96: ... Check the piston cylinder on the PTO Clean the air supply system Refer to vehicle manufacturer s instructions Check that the PTO engages correctly Return the vehicle to service Check the PTO for leaks Reassemble and install the PTO on the transfer case Road test the vehicle to confirm the problem is corrected No Remove the PTO from the transfer case Disassemble the PTO and inspect the bearings sh...

Page 97: ... Refer to OEM instructions Check the piston cylinder on the declutch Clean the air supply system Refer to OEM instructions Verify the transfer case shifts correctly Return the vehicle to service Check the PTO for leaks Reinstall the transfer case onto the vehicle Road test the vehicle to confirm the problem is corrected No Remove the transfer case from the vehicle Follow disassembly procedures Ins...

Page 98: ... stationary Air system contaminated Shift transmission to neutral Shift transfer case to neutral Shift transmission into 1st gear press lightly on the accelerator PTO models only Return the vehicle to service Air blowing out the housing breather Air blowing out the neutral breather or port Yes No Return vehicle to service Reinstall transfer case in vehicle and return vehicle to service Problem fix...

Page 99: ...of overheating to prevent damage to components Do Not Install API GL 5 Oils CAUTION Meritor does not approve petroleum based and multi viscosity oil NEVER install API GL 5 oils which contain extreme pressure EP additives These additives can form sludge at normal operating temperatures Damage to components can result Use only SAE Grade full synthetic 40W or 50W oil Meritor specification O 81 in the...

Page 100: ...HER REAR OUTPUT POSITION Figure 11 3 Seals CAUTION Always use the correct tools and procedures when replacing seals to prevent incorrect installation and help prevent seals from leaking Seals keep lubricant in and dirt out of a component When they are worn or damaged seals leak and produce low lubricant levels which may damage components Always replace unitized seals after yokes have been removed ...

Page 101: ...tall API GL 5 oils which contain extreme pressure EP additives These additives can form sludge at normal operating temperatures Damage to components can result Use only SAE Grade full synthetic 40W or 50W oil Meritor specification O 81 in the transfer case CAUTION When servicing the transfer case add the specified lubricant until the oil level is even with the bottom of the fill hole NEVER overfil...

Page 102: ...e Before the priming procedure is started the volume of the cooling system must be added through the alternate fill location breather hole Figure 11 5 NOTE At this point the transfer case oil level will be higher than the bottom of the primary oil fill hole After priming is completed this level will drop Check the oil fill level in the transfer case and ensure it is to the bottom of the fill hole ...

Page 103: ...over Using a 1 4 square drive tighten the pipe plug to 15 lbs ft 20 Nm If the diagnostic port on the tee fitting reinstall the cap WARNING Use caution checking the oil level as it may be hot 6 Check the oil fill level in the transfer case within 15 minutes of priming Use caution when removing the oil fill plug as the oil may be hot NOTE The oil level may be higher than the oil fill plug after 15 m...

Page 104: ...an occur if TP 9441 requirements are not followed CAUTION Transfer case oil fill volumes do not include additional oil needed to fill the OEM oil cooler and lines The transfer case oil fill volumes listed below are for reference only Fill to the bottom of the oil fill hole for proper oil level Table H Transfer Case Oil Fill Volumes Model Pints Liters MTC 4208X 13 25 6 27 MTC 4208XLEC 13 50 6 39 MT...

Page 105: ...USA 12 Specifications Torque Specifications Standard MTC 4213X MTC 4208XP and MTC 4210XP STANDARD MODEL MTC 4208XP AND MTC 4210XP OIL COOLER READY MODEL MTC 4213X 4007123a 10 FRONT 4 15 14 13 1 3 12 11 8 24 9 FRONT 10 8 7 19 22 20 23 21 16 18 6 13 4 5 17 2 2 Figure 12 1 ...

Page 106: ...00 949 1220 10 Bearing Cage Capscrews 85 115 115 156 11 Shaft Lock Nut 700 900 949 1220 12 Oil Pump Capscrews3 22 29 29 39 13 Shift Cylinders4 80 100 108 136 14 Male Connector 35 49 15 Fitting Screen 35 50 48 68 16 Neutral Breather Bushing 10 14 17 Female Connector 25 34 18 3 8 9 5 mm Plug2 20 27 19 Elbow2 20 27 20 Fitting 25 30 34 41 21 Fitting 25 30 34 41 22 Capscrews 10 13 14 18 23 Capscrews 10...

Page 107: ...ted in USA 12 Specifications Standard MTC 4208X XL XLEV and MTC 4210X XL XLEV 13 13 23 26 4 MTC 4208XL AND MTC 4210XL MTC 4208X AND MTC 4210X 4007200a 2 1 14 4 12 13 21 11 20 4 9 19 4 4 13 10 11 3 2 3 16 18 8 7 16 5 5 22 25 24 8 7 5 17 15 22 6 18 9 19 Figure 12 2 ...

Page 108: ...00 949 1220 12 Oil Pump Capscrews3 22 29 29 39 13 Shift Cylinders4 80 100 108 136 14 Male Connector 35 48 15 Fitting Screen 35 50 48 68 16 Neutral Breather Bushing 10 14 17 Female Connector 25 34 18 3 8 9 5 mm Plug2 20 27 19 Elbow2 20 27 20 Restrictor Plug2 15 20 21 7 16 x 1 75 PTO Cover Capscrews 60 75 81 102 22 Plug 25 34 23 Oil Pump Cover Capscrews3 10 13 14 18 24 Elbow 20 27 25 Connector 20 27...

Page 109: ...Meritor recommends using one of the two methods below when towing to prevent damage to the transfer case NOTE For complete towing information and instructions on axle shaft removal refer to Technical Bulletin TP 9579 Driver Instruction Kit METHOD 1 Remove both axle shafts from the axles that will remain on the road when the vehicle is transported METHOD 2 Remove the drive shafts from axles that co...

Page 110: ...contact Meritor for a price and delivery quotation The manufacture of these tools should be carried out by professional machinists and certified welders following typical good workmanship procedures and safe practices Holding Fixture 905473 140 4007380a ø3 00 2 00 0 50 0 50 ø4 00 THRU YOKE 17TYS38 76 5 00 4 00 2 20 5 59 2 60 2 804 8 00 DRILLTHRU FOR 1 2 20 SOC HEAD SCREW 4 PLACES 4 00 2 362 2 360 ...

Page 111: ...river 905473 92 4007159a 0 18 0 25 0 03 X 45 TYP 1 85 2 440 DIA 2 0 KNURL 0 50 1 00 0 13 X 45 2 56 DIA 3 00 DIA 3 40 3 50 DIA 2 50 DIA 0 41 DIA 4 00 Figure 14 2 Bearing Driver 4FI20 27110 000008 4012346a 0 568 1 560 Assembled Tool 2 pieces 4FI20 27110 000008 D01 4FI20 27110 000008 D02 Figure 14 3 ...

Page 112: ...bearing driver guide into the bore of Tool A bearing driver 2 Install a 3 16 O D x 1 2 long roll pin through the 1 4 x 2 1 2 long slot of Tool A and into the 3 16 hole in Tool B The roll pin can be obtained from McCaster Carr part number 98296 A975 QTY 2 4140 PRE HARDENED Figure 14 4 Bearing Driver Guide 4FI20 27110 000008 D02 4012354a 0 250 Ø1 608 3 125 Ø2 108 0 13X45 0 06X45 3 16 DRILL THRU BOTH...

Page 113: ...9 X 45 TYP 0 03 X 45 2 PLCS 0 03 R 0 03 R 0 12 R 6 23 2 25 ø2 70 DIA 4 0 KNURL 0 90 0 50 6 88 ø4 0 DIA ø2 6400 DIA ø3 25 DIA NOTE Not available from Meritor Figure 14 6 Bearing Cup Driver 910203 36 4007157a 3 65 4 810 4 808 DIA 4 450 DIA 4 0 DIA 1 15 1 35 4 15 0 250 45 1 76 3 48 DIA 3 980 3 978 DIA 0 09 RAD TYP MIN UNDERCUT Figure 14 7 ...

Page 114: ... Tool Assembly Instructions Use a fastener to attach Tool A driver handle to Tool B bearing driver face tool USE FOR INSTALLATION OF MTC 4210XLEV FORWARD AND REAR IDLER SHAFT BEARING CUPS JM207010 AND 33821 Figure 14 8 4FI20 27110 000007 D02 4012345a 0 25 0 63 0 875 1 13 Ø3 063 Ø3 69 TOOL B 102 6 MIN UNDER CUT Ø3 454 DRILL AND C BORE FOR 1 2 30 SDC HR SCR BEARING CUP DRIVER FOR CUPS JM207010 AND 3...

Page 115: ...1 Revised 06 22 Page 113 Printed in USA 14 Tools Bearing Cup Driver 910203 37 3 48 DIA 4007158a 0 50 4 997 4 995 DIA 4 637 DIA 4 0 DIA 1 09 1 50 1 56 4 34 0 250 45 3 980 3 978 DIA 0 09 RAD TYP MIN UNDERCUT 4 980 4 976 DIA Figure 14 10 ...

Page 116: ...Copyright Meritor Inc 2022 MM 0861 Revised 06 22 Page 114 Printed in USA 14 Tools PTO Bearing Cone Driver 4007162a 4 00 3 000 0 250 0 38 5 375 3 500 8 00 4 50 R 0 38 0 44 Figure 14 11 ...

Page 117: ...move not needed Disassemble and turn the fingers out both sides Grind to sharp the upper edge to maximize cup contact Grind the corner for clearance USE FOR REMOVAL OF IDLER SHAFT BEARING CUPS ON MTC 4208XL XLEV AND MTC 4210XL XLEV Tool Instructions Obtain Snap On tool Part CJ82B and modify as described here Figure 14 12 ...

Page 118: ...Rights Reserved Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability Meritor Heavy Vehicle Systems LLC reserves the right to revise the information presented or to discontinue the production of parts described at any time MM 0861 Revised 06 22 ...

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