Meritor MTC-4208X Series, Service Manual, Page: 83 / 120

Copyright Meritor, Inc., 2020 Printed in USA
MM-0861 / Revised July 2020
Page 79
6 Assembly
MTC-4208/10 XLEC Oil Fill & Pump
Pressure Test
1. Check and, if necessary, fi ll the transfer case, cooler and lines
as follows. Use Meritor-approved lubricant, full-synthetic 50W or
40W oil. Refer to publication TP-90114 - Transmission Lubricant
Specifi cations for a list of approved distributors. Fill transfer case
to a total volume of 16 pints (7.57 liters).
2. Perform an oil pump pressure check as follows.
a. Remove the pipe plug from the diagnostic port of the pump
cover using a 1/4” square drive. Figure 6.52.
Figure 6.52
PIPE PLUG
4016831a
b. Install a pressure gauge to the diagnostic port using a
suitable 1/4” pipe fi tting.
NOTE: A pressure gauge with a maximum reading of 100
psi (6.89 bar) must be used for this model.
c. Use one of the following methods to test the oil pump
pressure.
• Install the gauge on a hose long enough to position the
gauge inside the vehicle cab and road test the vehicle for at
least one mile (1.6 km), at a speed of at least 30 mph (48
km/h).
• If the transfer case is not equipped with a neutral range
shift, remove the rear drive shaft from 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 OIL PRESSURE DOES NOT REACH AT LEAST 10 PSI
(0.69 BAR), TURN THE VEHICLE OFF. DO NOT REPEAT THE
ROAD TEST. DAMAGE TO COMPONENTS CAN RESULT.
d. Check the pump pressure gauge to verify it has reached an
oil pump pressure of 10 psi (0.69 bar).
• A positive pressure of at least 10 psi (0.69 bar) indicates the
pump and oil cooler system are correctly primed.
• If oil pressure is not at least 10 psi (0.69 bar), turn the
vehicle off. Do not repeat the test or damage to components
can result. Recheck the oil fi ll level at the transfer case fi ll
port on the front case. Ensure the oil is at the bottom of the
fi ll hole. Verify the hose and fi ttings are tight and no leaks are
evident.
3. Remove the pressure gauge and fi tting from the diagnostic port.
4. Apply Loctite 592 or equivalent pipe sealant to the pipe plug and
reinstall it into the diagnostic port of the pump cover.
5. Using a 1/4” square drive, tighten the pipe plug to 15 lb-ft (20
N∙m).
6. Check the oil fi ll in the transfer case. The level should be to the
bottom of the fi ll hole.
7. Add lube oil as necessary to bring the level up to the bottom of
the fi ll hole.
8. Reinstall the plug and tighten to 35 lb-ft (48 N∙m).