Meritor MTC-4208X Series, Service Manual, Page: 57 / 120

Copyright Meritor, Inc., 2020 Printed in USA
MM-0861 / Revised July 2020
Page 53
5 Prepare Parts for Assembly
• Chipped or cracked splines on the output shaft.
CHIPPED
SPLINES
• Cracks along the yoke splines, bearing journal abutments, or
cross-drilled holes. Magnafl ux may be necessary to see small
cracks.
PTO Components
Inspect the PTO housing, shaft, taper bearings, shift collar, 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.
Magnafl ux 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.
• Cracked or missing tangs on the shift fork arms.
• The sensor ball sticks or does not return to its resting position.
The sensors do not complete a circuit when tested with a volt-
ohm meter (VOM).
• Check all shift forks and slots in sliding clutches for wear or
discoloration due to heat.
High & Low Shifting Components
Inspect the shift collar, shift fork, shift shaft, retaining pins, shift cylin-
der, piston, o-ring and case halves for damage. If any of the following
conditions exist, replace or repair the component.
• Cracked or missing tangs on the shift fork arms.
• Chipped or cracked shifting splines on the shift collar.
• Cracks or deep gouges on the shift shaft.
• The retaining pins in the shift shaft are not 0.100” (2.54 mm)
above the shaft diameter. Remove and set to the correct position.
• Gouges on the inside of the shift cylinder.
• Torn or feathered areas on the o-ring.
• Deep gouges in the shifting bores of the case 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 checks.
1. Inspect the oil for metal shavings, dirt, and consistency. Perform an
analysis if the oil appears contaminated.
2. Check the magnets for metal shavings. A small amount of metal
shavings is normal. However, excessive build-up indicates gear and
bearing damage. Thoroughly remove all metal shavings from the
magnets. The magnets must be fi rmly fastened to the case.
3. Check the sump screen. Remove any material that may restrict oil
fl ow through the mesh.
4. Check the oil line for damage. Replace if it is dented or kinked.
Internal Oil Pump
1. Inspect the seals closely. Look for nicks and tears on all sealing lips.
Any damage is likely to result in a seal leak.
2. Check the pump for easy rotation. If the internal gear does not spin
easily or jams when rotating the crescent plate, replace the pump.
Also inspect for signs of heat/discoloration.
3. Inspect the input shaft and oil pump splines for damage.
4. Verify the relief valve spring and bushing are in good condition and
replace, 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 pump pressure check
instructions in the fi nal assembly procedures
Transfer Case Halves
Inspect the case halves for cracks and internal wear. If any of the follow-
ing conditions exist, replace the damaged parts.
• A crack in either case half.
• Deep gouges in the shifting bores.
• Signs of bearing cup rotation.