Meritor MTC-4208X Series, Service Manual, Page: 61 / 120

Copyright Meritor, Inc., 2020 Printed in USA
MM-0861 / Revised July 2020
Page 57
6 Assembly
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, “Bearing Cone Driver (905473-82)” on page 108,
and press to push the forward 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. Rotate the shaft so the rear half of the shaft is facing UP. Use
a sleeve, tool number 905473-92, and press to push the rear
bearing cone DOWN until it is fully seated. Refer to “Tools” on
page 107 for tool drawings. 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.
Assemble the Rear Output Shaft Subassembly
(MTC-4208X/XP/XL/XLEV & MTC-4210X/XP/XL/XLEV
Only)
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, “Bearing Cone Driver
(905473-82)” on page 108, 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 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 models
use “Bearing Cone Driver (905473-82)” on page 108) (XLEV
models use “Bearing Driver (4FI20-27110-000008-D01)” on
page 109), 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 orifi ce.
4. Install the internal oil pump using the following procedure.
a. Pack lithium-complex grease, Meritor specifi cation 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 N∙m).
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 fi t.
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 108, 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
N∙m). Figure 6.6.
Figure 6.6
4007182a
RESTRICTOR
PLUG
BEARING
CONE