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Meritor MTC-4208X Series Service Manual Download Page 104

Copyright Meritor, Inc., 2020

MM-0861 / Revised July 2020
Page 100

Printed in USA

10

     Lubrication & Maintenance

4.  The oil level must be even with the bottom of the fi ll plug.

If oil fl ows from the fi ll plug port when the plug is 
loosened:

The oil level is too high. Drain the oil to the bottom of the fi ll plug 
hole. Ensure cooler oil line routing prevents back fl ow to the 
transfer case sump

NOTE:

 Oil can drain back from the oil cooler, giving the 

appearance of an over full condition.

If the oil level is below the fi ll/level plug hole:

Add SAE Grade full synthetic 40W or 50W oil, Meritor 
Specifi cation 0-81, until oil is even with the bottom of the fi ll hole.

5.  Install and tighten the fi ll plug to 35-50 lb-ft (47-68 N∙m). 

6.  Test drive the vehicle for at least one mile (1.6 km). Allow the oil 

to settle for fi ve minutes and recheck the fl uid level. Top off the oil 
level by adding oil to the fi ll opening. Reinstall and tighten the fi ll 
plug to 35-50 lb-ft (47-68 N∙m). 

Figure 10.5

STANDARD MODEL FRONT COVER

4007128a

OIL FILL

PLUG

MAGNETIC

DRAIN PLUG

FRONT

Drain & Replace the Oil

1.  Park the vehicle on a level surface. Place a large container under 

the transfer case.

2.  Remove the magnetic drain plug from the bottom of the transfer 

case. Drain and discard the oil correctly. Clean the plug. Figure 
10.5.

3.  Install and tighten the drain plug to 35-50 lb-ft (47-69 N∙m). 

Clean the area around the fi ll plug. Remove the fi ll plug from the 
transfer case. 

4.  Add SAE Grade full-synthetic 40W or 50W oil, Meritor 

specifi cation O-81, into the transfer case until the oil level is even 
with the bottom of the fi ll plug hole. Install and tighten the fi ll plug 
to 35-50 lb-ft (47-68 N∙m). 

5.  Test drive the vehicle for at least one mile (1.6 km). Allow the oil 

to settle for fi ve minutes and recheck the fl uid level. Top off the oil 
level by adding oil to the fi ll opening. Reinstall and tighten the fi ll 
plug to 35-50 lb-ft (47-68 N∙m). 

Transfer Case Inspection

Visually inspect the transfer case daily for any leaks. The oil level 
should be inspected every 1,000 miles (1069 km), 100 hours or every 
month, whichever comes fi rst. In addition, the transfer case should be 
inspected for leaks and the correct oil level before and after extended 
time high speed road trips. Areas to inspect are:

•  Cooler lines and fi ttings

• Seals

• Breather

•  Fill and drain plugs

•  Pump inlet tube and fi ttings

•  Gaskets and shims

•  During the inspection visually check to ensure the transfer case 

oil level is to the bottom of the oil fi ll hole.

Summary of Contents for MTC-4208X Series

Page 1: ...July 2020 MTC 4208X XL XP XLEV XLEC MTC 4210X XL XP XLEV XLEC MTC 4213X SERIES TRANSFER CASES MAINTENANCE MANUAL MM 0861 Copyright Meritor Inc 2020 MM 0861 Revised July 2020 Page FC Printed in USA...

Page 2: ...d observe all Warning and Caution hazard alert messages in this publication They provide information that can help prevent serious personal injury damage to components or both 3 Follow your company s...

Page 3: ...ase 41 Section 5 Prepare Parts for Assembly 51 Hazard Alert Messages 51 Clean and Dry Parts 51 Inspect Parts 52 Section 6 Assembly 56 Hazard Alert Messages 56 Gear Shaft Subassembly Build Up 56 Gear S...

Page 4: ...ormation 98 Check Adjust the Oil Level 100 Drain Replace the Oil 101 Transfer Case Inspection 101 Section 11 Torque Speci cations 104 Standard MTC 4213X MTC 4208XP MTC 4210XP 104 Standard MTC 4208X XL...

Page 5: ...r 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...

Page 6: ...SA 1 Exploded Views MTC 4208X XP Transfer Case Front Cover 4007389a 1 2 3 4 12 43 10 9 12 13 14 15 16 28 29 28 29 34 35 36 23 24 26 27 31 44 11 15 6 2 42 39 41 8 7 53 52 51 54 FRONT OUTPUT DECLUTCH 25...

Page 7: ...nector 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...

Page 8: ...020 MM 0861 Revised July 2020 Page 4 Printed in USA 1 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...

Page 9: ...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 Cups 22...

Page 10: ...inted in USA 1 Exploded Views MTC 4208XL Transfer Case Front Cover 4007102a 10 14 19 29 30 32 33 31 34 35 36 44 42 25 26 28 27 50 24 30 29 22 39 42 23 17 18 38 39 42 43 42 41 38 42 40 45 46 47 42 36 3...

Page 11: ...g 18 Front 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 Yo...

Page 12: ...d in USA 1 Exploded Views 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 3 401...

Page 13: ...ng 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...

Page 14: ...SA 1 Exploded Views MTC 4208XLEV XLEC Transfer Case Front Cover 4011709b 7 10 17 30 31 40 33 35 34 32 36 37 38 45 42 25 26 29 27 24 31 30 21 20 23 15 16 43 20 44 20 54 20 55 53 52 51 20 49 50 47 48 49...

Page 15: ...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 Fron...

Page 16: ...tor Inc 2020 MM 0861 Revised July 2020 Page 12 Printed in USA 1 Exploded Views MTC 4210X XP Transfer Case Rear Cover 17 4007388a 2 1 6 8 9 10 6 12 13 19 18 1 20 20 26 27 5 3 4 1 25 24 2 5 21 5 23 22 2...

Page 17: ...O 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...

Page 18: ...in USA 1 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 51 50 8 49 FRONT OUTPUT DECLUTCH 23 28...

Page 19: ...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...

Page 20: ...M 0861 Revised July 2020 Page 16 Printed in USA 1 Exploded Views MTC 4210XL Transfer Case Rear Cover 24 20 19 17 18 16 21 21 22 23 22 21 21 33 4 2 34A 33A 34 3 7 8 9 10 12 13 14 6 5 4 1 2 4007101a 32...

Page 21: ...ton 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...

Page 22: ...rinted in USA 1 Exploded Views MTC 4210XL Transfer Case Front Cover 4007102a 6 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 19 17 36 17 45 12 17 46 44 43 42 17 40 41...

Page 23: ...ing 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 F...

Page 24: ...ed in USA 1 Exploded Views 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 40...

Page 25: ...ng 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...

Page 26: ...A 1 Exploded Views MTC 4210XLEV XLEC Transfer Case Front Cover 4011709b 7 10 17 30 31 40 33 35 34 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...

Page 27: ...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 Fron...

Page 28: ...vised July 2020 Page 24 Printed in USA 1 Exploded Views MTC 4213X Transfer Case Rear Cover 9 8 5 10 11 12 13 13A 7 15 16 14 38 17 21 23 24 29 28 30 7 31 32 23 27 25 39 40 41 36 35 34 33 37 21 23 4 3 2...

Page 29: ...g 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 Sha...

Page 30: ...Revised July 2020 Page 26 Printed in USA 1 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 4007...

Page 31: ...l 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 S...

Page 32: ...Copyright Meritor Inc 2020 MM 0861 Revised July 2020 Page 28 Printed in USA 1 Exploded Views MTC 4208XP 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 33: ...r 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...

Page 34: ...ing in High 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 E...

Page 35: ...instru ment 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 engage...

Page 36: ...MTC 4208XL MTC 4210XL HIGH RANGE GEAR EXTERNAL OIL PUMP REAR OUTPUT SHAFT LOW RANGE GEAR DOUBLE IDLER GEAR INPUT SHAFT FRONT OUTPUT SHAFT Figure 2 6 4011713a MTC 4208XLEV MTC 4210XLEV HIGH RANGE GEAR...

Page 37: ...le is stationary Apply the parking brake with the trans mission in Neutral on automatic or manual transmissions If the clutch does not fully engage Turn the steering wheel in one direction and rock th...

Page 38: ...ROM COOLER DRAIN PLUG MAGNETIC PLUG OIL PUMP OUTLET TO COOLER 4012334 a Figure 2 11 OIL PUMP CROSSOVER TUBE CONNECTION PUMP INLET CONNECTION OIL PUMP OUTLET TO COOLER MTC 4208 10 XLECVARIANT PUMP COVE...

Page 39: ...ER IF EQUIPPED NEUTRAL PORT PTO EQUIPPED ONLY Full Torque Power Take Off PTO CAUTION NEVER ENGAGE THE FULL TORQUE POWER TAKE OFF PTO WHEN THE TRANSFER CASE PROP SHAFTS ARE TURNING DAMAGE TO THE TRANSF...

Page 40: ...R 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 vehic...

Page 41: ...MP COVER 4014941d Figure 3 5 MTC 4208 10 XLEC DRIVER SIDE MOUNTED COOLER OIL PUMP CROSSOVER TUBE TEE FITTING OE COOLER LINE CONNECTION 4016827a P CLAMP ASSEMBLY Figure 3 6 MTC 4208 10XLEC PASSENGER SI...

Page 42: ...HOLES MOUNTING HOLES Figure 3 8 4012326a MOUNTING HOLES NOTE Eyebolts permit easier lifting of the transfer case 15 Install eyebolts in the lifting holes located in either half of the transfer case h...

Page 43: ...08XL MTC 4210XL SHOWN 4007108a OILTUBE b Disconnect the oil cooler to pump cover oil lines c Plug the oil lines and cap the oil cover ttings d Remove the external oil pump housing from the transfer ca...

Page 44: ...ly 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...

Page 45: ...XL MTC 4210XL INLET 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 4 6 MTC 4208XLEV MTC 4210XLE...

Page 46: ...ing forward pressure to the pump assembly and disengage the assembly from the oil pump drive pins located on the rear half on the input shaft Figure 4 11 Figure 4 11 4007115a PUMP PIN SLOT DRIVE PIN I...

Page 47: ...fer case models MTC 4208X XP MTC 4210X XP remove the PTO cover or PTO whichever applies Use a 3 socket to remove the large retaining nut and washer from the rear half of the input shaft Use a yoke too...

Page 48: ...nsfer cases 5 Shift the transfer case into high range using compressed air at the high range port of the shift cylinder Figure 4 15 Figure 4 15 Figure 4 15 4000191c HIGH RANGE PORT LOW RANGE PORT BLOW...

Page 49: ...he inner piston reinstall and hand tighten the shift cylinder Apply air to the high gear input port When the air pressure pushes the inner piston UP remove the snap ring and inner piston Figure 4 20 F...

Page 50: ...shift fork and spring as an assembly 11 Remove the shift cylinder and push rod from the front case 12 Remove the two locating dowel pins Note their correct location Disassemble the Front Output Shaft...

Page 51: ...r output shaft outer bearing cup from the rear cover if required Discard the cone and cup 4 Inspect the rear output shaft inner bearing cone and cup for wear or damage Replace a worn or damaged bearin...

Page 52: ...red roller bearing cone and cup a Remove the six bolts retaining the oil pump to the input bearing cage b Mark the position of the pump to the cage for reassembly Figure 4 32 Figure 4 32 4000201b OIL...

Page 53: ...ng Cups 1 Correctly support the transfer case half 2 Use a suitable puller to remove the bearing cups from the transfer case half Figure 4 33 Figure 4 33 4007155a BEARING CUP PULLER BEARING CUP 3 Clea...

Page 54: ...care not to damage the ground surfaces 3 NEVER clean ground or polished parts in a hot solution tank water steam or alkaline solution to avoid damaging the surfaces Clean Rough Parts 1 Clean rough par...

Page 55: ...A visible roller groove is worn in the inner race surfaces of the cup or cone The groove can be seen at the small or large diameter end of both parts Deep cracks or breaks appear in the surfaces of th...

Page 56: ...ar Replace the pump if these conditions exist 8 Remove and inspect the plug at the end of the input shaft Verify the ori ce is clear of debris Helical Gears Inspect the helical gear teeth splines and...

Page 57: ...se halves Oil Lubrication System The lubrication system is extremely important to the performance of the transfer case Inspect all parts closely for excessive wear or damage Perform the following chec...

Page 58: ...fer case halves using a suitable gasket scraper or wire wheel 4 Press new bearing cups into the case halves as necessary Refer to Assembly for bearing settings and starting shim pack procedures if req...

Page 59: ...S POSSIBLE CAUTION ALTHOUGH MERITOR DOES NOT RECOMMEND ITS USE IN TRANSFER CASES IF A FORMED IN PLACE GASKET IS USED FOR REPAIRS EXTREME CAUTION MUST BE EXERCISED TO PREVENT COMPOUND FROM ENTERING BEA...

Page 60: ...drawings Press down only on the inner race of the bearing during installation Use a 0 002 shim or feeler gauge to verify the bearing is correctly seated Figure 6 4 Figure 6 4 4006926b SLEEVE TOOL 905...

Page 61: ...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 assembl...

Page 62: ...ORTS b Place the bearing cone on the race in the bearing cage c MTC 4208X XP MTC 4210X XP transfer cases only Insert the relief valve and spring into the relief port of the input bearing cage Install...

Page 63: ...lling the input bearing cage to prevent damage to the o ring 8 Place the oil pump if equipped and input bearing cage assembly over the input shaft The drive teeth on the inner pump rotor must engage t...

Page 64: ...LEV and double gear idler shaft assemblies all models Figure 6 15 Figure 6 15 4000203a 4 Position the clutch collar onto the shift fork Position the shift fork and clutch collar onto the front output...

Page 65: ...age shim pack thickness is 0 056 3 Lubricate the input bearing cage large o ring internal oil pump if equipped helical drive gear and bearing cone before installation Use SAE Grade full synthetic 40W...

Page 66: ...being replaced install a starting shim pack thickness of 0 036 0 91 mm or use the same thickness as removed Figure 6 20 Figure 6 20 4007369a SHIMS SPACER 5 Use a bearing cone driver tool number 90547...

Page 67: ...L XLEV MTC 4210X XP XL XLEV input shaft initial starting shim pack thickness is 0 036 MTC 4208XP MTC 4210XP upper rear output yoke does not require an end play check For all other locations determine...

Page 68: ...end plays are set 1 Install the front output shaft yoke Temporarily tighten the yoke nut to 700 900 lb ft 949 1220 N m 2 Rotate the output shaft several times to seat the bearings 3 Set up a dial ind...

Page 69: ...t locations on the front of the case 3 To prepare to check shaft bearing end play insert a 1 2 13 bolt into the shaft through the pipe plug hole until the bolt is fully seated The bolt should extend o...

Page 70: ...ft bearing cones spacer and shims yoke into the rear cover Temporarily tighten the yoke nut to 700 900 lb ft 949 1220 N m Place the rear cover on the bench to measure bearing end play Refer to the bea...

Page 71: ...C 4213 transfer case If the end play is greater than 0 006 0 152 mm for MTC 4208 and MTC 4210 transfer cases or 0 004 0 051 0 102 mm for the MTC 4213 transfer case Remove shims to decrease end play If...

Page 72: ...2 0 13 mm 1 0 08 mm 0 34 mm 1 0 25 mm 1 0 13 mm 0 38 mm 1 0 25 mm 2 0 08 mm 0 41 mm 5 After selecting the correct shim combination place the shims in the bottom of the bearing bore Refer to the explod...

Page 73: ...pre covered apply Loctite 272 sealant to the rst three threads of the cover to case capscrews 5 Install all cover to case capscrews and at washers Tighten the capscrews to 60 75 lb ft 81 102 N m 6 Re...

Page 74: ...MANUFACTUR ER S INSTRUCTIONS BEFORE USING A SOLVENT CLEANER THEN CAREFULLY FOLLOW THE INSTRUCTIONS ALSO FOLLOW THE PROCEDURES BELOW Wear eye protection Wear clothing that protects the skin Work in a w...

Page 75: ...gure 6 34 The yoke must be fully pressed into the sleeve driver until the end of the yoke bottoms out in the sleeve driver This will correctly position the sleeve on the yoke When correctly seated the...

Page 76: ...y hold the shift shaft in place 3 Grease the o ring on the piston and install the piston into the cylinder 4 Apply a 1 8 3 mm bead of Loctite 277 sealant to the rst three threads of the shift cylinder...

Page 77: ...Figure 6 41 Figure 6 41 MTC 4208XL XLEV AND MTC 4210XL XLEV 4007114a PIN DOWEL PIN DOWEL INPUT SHAFT 2 Install the pump spring into the ori ce at the rear of the input shaft 3 Place the pump onto the...

Page 78: ...mp cavity Damage to the pump can result Figure 6 45 Figure 6 45 MTC 4208XL XLEV MTC 4210XL XLEV 4006326d Align PUMP REVERSING TAB PUMP COVER LOCTITE 518 SEALANT CAUTION VERIFY THE PUMP COVER PIN IS TH...

Page 79: ...and washer 4 On MTC 4208XP and MTC 4210XP install the PTO engagement and disengagement switch assemblies if equipped Otherwise install a nut and washer into the open port 5 Reinstall all other pipe th...

Page 80: ...alf the rate as the input 9 Remove the air pressure 10 For PTO equipped cases apply 60 psi 4 14 bar or greater of air pressure to the neutral shift location Figure 6 50 11 Turn the input shaft by hand...

Page 81: ...ter pressure hose and the pressure gauge onto the other end 3 Connect the female tting to the unused port of the diagnostic tee tting Figure 6 51 4 Route the gauge to a position where it can be viewed...

Page 82: ...ral b Shift the transfer case to high and low range and back to Neutral c Attempt to place the vehicle back into drive and repeat the procedure until the transfer case goes into Neutral CAUTIONS RUN T...

Page 83: ...rom the transfer case rear output yoke Place the transfer case in high range 2 wheel drive and the transmission in 4th gear 1 1 ratio and run the engine at least 400 rpm for 20 seconds WARNING IF THE...

Page 84: ...TURER S EMERGENCY PROCE DURES AND GET CHECKED BY A PHYSICIAN AS SOON AS POSSIBLE TAKE CARE WHEN USING LOCTITE ADHESIVE TO AVOID SERIOUS PERSONAL INJURY READ THE MANUFACTURER S INSTRUCTIONS BEFORE USIN...

Page 85: ...O 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 Opti...

Page 86: ...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 Interna...

Page 87: ...se a 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 7 2 2 Apply a 1 8 46 mm bead of RTV silicone gasket material around...

Page 88: ...elow to verify the PTO clutch engages correctly PTO Without an Optional Indicator Switch 1 Remove the switch port screw and washer Figure 7 4 2 Measure the PTO push rod travel to verify the travel is...

Page 89: ...breather PTO Disassembly Once the PTO has been removed according to the procedure in Section 4 use the following procedure for disassembly WARNING TAKE CARE WHEN REMOVING THE SPRING LOADED PTO CAP SE...

Page 90: ...housing Slide the bearing spacer onto the splined end of the shaft d With the bearing spacer in position the second bearing cone can be heated to 200 F 93 C and installed onto the shaft Figure 7 10 F...

Page 91: ...re test the PTO shifter for air leakage by performing the following steps a With the correct tting installed into the air control port apply a pressure of 90 psi 6 2 bar b Shut off the air supply CAUT...

Page 92: ...vehicle with the hydraulic roller jack 3 Install the transfer case into the vehicle with the mounting bolts Tighten the bolts to the torque speci cation supplied by the vehicle manufacturer 4 Connect...

Page 93: ...er case Tighten to 20 lb ft 27 2 N m 4 Connect the oil return line JIC tting to the transfer case Tighten to 20 lb ft 27 2 N m Figure 8 2 MTC 4208XL MTC 4210XL INLET TUBE FITTING INLET TUBE PUMP COVER...

Page 94: ...The 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 Inst...

Page 95: ...e breather is 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 t...

Page 96: ...the transfer 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 in...

Page 97: ...nufacturer s speci cations 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 mo...

Page 98: ...instructions 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...

Page 99: ...air pressure 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...

Page 100: ...r more Vehicle 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...

Page 101: ...s at this range should only occur in linehaul or utility applications that operate under high speed for long periods of time Do Not Install API GL 5 Oils CAUTION MERITOR DOES NOT APPROVE PETROLEUM BAS...

Page 102: ...N LEAK DAMAGE TO COMPONENTS CAN RESULT 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...

Page 103: ...CONTAIN EXTREME PRESSURE EP ADDITIVES THESE ADDITIVES CAN FORM SLUDGE AT NORMAL OPER ATING TEMPERATURES DAMAGE TO COMPONENTS CAN RESULT USE ONLY SAE GRADE FULL SYNTHETIC 40W OR 50W OIL MERITOR SPECIFI...

Page 104: ...the transfer case 2 Remove the magnetic drain plug from the bottom of the transfer case Drain and discard the oil correctly Clean the plug Figure 10 5 3 Install and tighten the drain plug to 35 50 lb...

Page 105: ...FER CASE OIL CAPACITY Model Pints Liters MTC 4208X 14 0 6 62 MTC 4208XLEC 16 0 7 57 MTC 4208XLEV 12 0 5 68 MTC 4208XP 14 0 6 62 MTC 4210X 14 0 6 62 MTC 4210XLEC 16 0 7 57 MTC 4210XLEV 12 0 5 68 MTC 42...

Page 106: ...in USA 11 Speci cations Torque Speci cations Standard MTC 4213X MTC 4208XP MTC 4210XP Figure 11 1 STANDARD MODEL MTC 4208XP AND MTC 4210XP OIL COOLER READY MODEL MTC 4213X 4007123a 10 FRONT 4 15 14 1...

Page 107: ...900 949 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...

Page 108: ...104 Printed in USA 11 Speci cations Standard MTC 4208X XL XLEV MTC 4210X XL XLEV Figure 11 2 13 13 23 26 4 MTC 4208XL MTC 4210XL MTC 4208X MTC 4210X 4007200a 2 1 14 4 12 13 21 11 20 4 9 19 4 4 13 10 1...

Page 109: ...Lock Nut 700 900 949 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 48 15...

Page 110: ...E 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 Technica...

Page 111: ...ings or contact Meritor for a price and delivery quotation The manufacture of these tools should be carried out by professional machinists and certi ed welders following typical good workmanship proce...

Page 112: ...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 Bearing Cone Driver 905473 82 Figure 13 3 Figure 13 3 4007160a 0 09 X 45 TY...

Page 113: ...ure 13 5 4012347a 0 389 0 250 30 R0 06 R0 125 0 13 X 45 2 PLACES TOOL A 0 50 R0 12 0 02 X 45 2 PLACES 4 95 2 25 2 50 4 45 0 80 1 83 2 743 2 148 3 25 2 582 Tool Assembly Instructions 1 Install Tool B b...

Page 114: ...6 4012354a 0 250 1 608 3 125 2 108 0 13X45 0 06X45 3 16 DRILL THRU BOTH SIDES HOLE FOR ROLL PIN SEE TOOL ASSEMBLY INSTRUCTIONS 3 625 1 375 R0 250 TOOL B QTY 2 4140 PRE HARDENED Bearing Cup Driver 910...

Page 115: ...00 COARSE KNURL 2 00 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 REAR IDLER SHAFT BEARING C...

Page 116: ...ed July 2020 Page 112 Printed in USA 13 Special Tools Bearing Cup Driver 910203 37 Figure 13 10 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...

Page 117: ...Copyright Meritor Inc 2020 Printed in USA MM 0861 Revised July 2020 Page 113 13 Special Tools PTO Bearing Cone Driver Figure 13 11 4007162a 4 00 3 000 0 250 0 38 5 375 3 500 8 00 4 50 R 0 38 0 44...

Page 118: ...ure 13 12 4012353a Remove not needed Disassemble and turn the ngers out both sides Grind to sharp the upper edge to maximize cup contact Grind the corner for clearance USE FOR REMOVAL OF IDLER SHAFT B...

Page 119: ......

Page 120: ...Meritor Heavy Vehicle Systems LLC 2135 West Maple Rd Troy MI 48084 USA 866 OnTrac1 668 7221 meritor com Copyright 2020 Meritor Inc Printed in USA 07 20 MM 0861...

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