Meritor MTC-4208X Series, Service Manual, Page: 49 / 120

Copyright Meritor, Inc., 2020 Printed in USA
MM-0861 / Revised July 2020
Page 45
4 Disassembly
High/Low Shift Cylinder Components
Use the following procedure to disassemble the high/low shift compo-
nents 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. Figure
4.18.
Figure 4.18
4007106a
NEUTRAL PORT
(MTC-4208 AND
MTC-4210 ONLY)
HIGH RANGE
PORT
LOW
RANGE
PORT
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 4.19.
Figure 4.19
4000192a
OUTER
SHIFT
PISTON
5. To remove the 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.
Figure 4.20
4000193b
INNER
SHIFT
PISTON
Split the Case Halves
1. Remove the capscrews securing the rear cover to the front case.
2. Use a pry bar to separate the two halves of the transfer case at
the pry tab locations around the case.
3. Place eyebolts into the rear cover lift holes located at the top and
bottom of the cover.
CAUTION
AS THE REAR COVER IS LIFTED, APPLY DOWNWARD PRES-
SURE ON THE SHIFT ROD TO PREVENT THE GEARS FROM
DROPPING OUT OF THE REAR TRANSFER CASE HALF.
4. Attach a suitable lifting device to the eyebolts. Lift the rear cover
from the front case. Figure 4.21.
Figure 4.21
4000187b
MOUNTING
HOLES
MOUNTING
HOLES
5. As the rear cover is lifted, verify the high and low shift shaft
remains in the case by placing pressure on the shaft while
separating the transfer case halves.