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Meritor T-2111 Series, Maintenance Manual, Page: 5 / 46

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Meritor T-2111 Series Maintenance Manual Download Page 5

T-2111 SERIES DCM BRAKES

1 Locknut-brake

1

2 Washer-brake

1

3 Nut-brake drum to flange

8

4 Spacer-brake drum to flange

8

5 Flange/Yoke-brake drum

1

6 Drum-brake

1

7 Lockwire-brake drum to hub capscrew

2

8 Bolt-brake drum to hub

8

9 Spacer-brake hub

1

10 Spring-brake shoe return

4

11 Brake Shoe and Lining Assy.

2

12 Lining-brake

2

13 Rivet-Lining to shoe

28

14 Strut Assy.

1

15 Camshaft

1

16 Backing Plate Assy.

1

17 Capscrew-cover adapter to cage

4

18 Washer-cover adapter to cage

4

19 Lever-brake

1

20 Washer-brake

1

21 Nut-lock

1

22 Deflector-brake adapter

1

23 Dust Shield

1

24 Oil Seal-brake bearing cage

1

25 Oil Seal-brake bearing cage

1

26 Cage Assy.-brake bearing

1

27 Capscrew-brake bearing cage

4

28 Washer-brake bearing cage capscrew

4

T-2111 SERIES PROPORTIONAL DIFFERENTIAL

29 Adapter-brake assy.

1

30 Cone-proportional diff. cage shaft

1

31 Cup-proportional diff. cage shaft

1

32 Capscrew-diff. cage to gear case cover

12

33 Washer-diff. cage to gear case cover

12

34 Cage-proportional diff.

1

35 Plug-oil drain

1

36 Shim-proportional diff. cage bearing 

2

spacer

37 Cup-proportional diff. cage shaft

1

38 Cone-proportional diff. cage shaft

1

39 Shaft-output outer

1

40 Gear-proportional diff. ring

1

41 Snap Ring-planet, pinion shaft

3

42 Washer-planet. pinion thrust

3

43 Pinion Planet Spider

3

44 Shaft-planet pinion

3

45 Spider Assy.-planet gear

1

46 Setscrew-planet pinion shaft

3

47 Snap Ring-outer output shaft

1

48 Gear-planet sun

1

49 Snap Ring-inner output shaft

1

50 Capscrew-output shaft cage

8

51 Washer-output shaft cage capscrew

8

52 Spacer-output shaft planet spider

1

53 Cover-proportional diff. gear case

1

54 Plug-oil fill hole

1

T-2111 SERIES MAIN CASE

55 Nut-input shaft lock

1

56 Washer-input shaft

1

57 Flange/Yoke-input shaft

1

58 Deflector-input shaft

1

59 Oil Seal-input shaft bearing cage

1

60 Oil Seal-input shaft bearing cage

1

61 Capscrew-input shaft bearing cage

8

62 Washer-bearing cage capscrew

8

63 Cage Assy.-input shaft bearing

1

64 Plug-transfer case

1

65 Plug-transfer case

1

66 Case-transfer

1

67 Plug-transfer case

1

68 Dowel-transfer case

2

69 Cup-input shaft bearing

1

70 Cone-input shaft bearing

1

71 Shaft-input

1

72 Shaft-input

1

72A Shaft-input

1

72B Retaining Plate-bearing

1

72C Capscrew-retaining plate

2

73 Bushing-input

1

74 Gear-input shaft

1

75 Spacer-input shaft

1

76 Cone-input shaft bearing

1

77 Cup-input shaft bearing

1

78 Plug-transfer case

1

79 Case-transfer

1

80 Plug-transfer case

1

81 Elbow-oil breather

1

82 Breather-transfer case

1

83 Shim-input shaft

3

84 Spacer-input shaft

1

85 Cage Assy.-input shaft bearing

1

86 Washer-bearing cage capscrew

8

87 Capscrew-input shaft bearing cage

8

88 Oil Seal-input shaft bearing cage

1

89 Oil Seal-input shaft bearing cage

1

90 Deflector-input flange/yoke

1

91 Flange/Yoke-input shaft

1

92 Washer-input shaft

1

93 Nut-input shaft

1

94 Capscrew-idler gear bearing cage

8

95 Washer-bearing cage capscrew

8

96 Cage Assy.-idler gear bearing

1

97 Shim-idler gear

3

98 Plug-oil suction

1

99 Plug-transfer case

1

100 Plug-oil fill

1

101 Locknut-transfer case capscrew

20

102 Washer-transfer case capscrew

20

103 Cup-idler gear bearing

1

104 Cone-idler gear bearing

1

105 Gear-idler

1

106 Cone-idler gear bearing

1

107 Cup-idler gear bearing

1

108 Plug-oil fill

1

108A Cap-filler pipe

1

108B Nipple-filler pipe

1

108C Elbow-filler pipe

1

108D Nipple-filler pipe

1

109 Cage Assy.-idler gear bearing

1

110 Washer-bearing cage capscrew

8

111 Capscrew-idler gear bearing cage

8

112 Nut-output shaft

1

113 Washer-output shaft

1

114 Flange/Yoke-output shaft

1

114A Deflector-output shaft

1

115 Oil Seal-output shaft

1

115A Oil Seal-output shaft bearing cage

1

116 Capscrew-output shaft bearing cage

4

117 Washer-bearing cage capscrew

4

118 Cage Assy.-output shaft bearing

1

119 Screw-name plate

2

120 Name Plate

1

121 Capscrew-transfer case

20

122 Washer-transfer case capscrew

20

123 Plug-oil drain

1

124 Plug-oil suction

1

125 Plug-transfer case

1

126 Cup-output shaft bearing

1

127 Cone-output shaft bearing

1

128 Spacer-output shaft bearing to gear

1

129 Shaft-output

—

130 Shaft-output

1

131 Bushing-output

1

132 Gear-output shaft

1

133 Cone-output shaft bearing

1

134 Cup-output shaft bearing

1

135 Collar-clutch

1

136 Plug-oil drain

1

137 Shim-output shaft

3

138 Spacer-output shaft

1

139 Cage Assy.-output shaft bearing

1

140 Washer-bearing cage capscrew

8

141 Capscrew-output shaft bearing cage

8

142 Oil Seal-output shaft

1

142A Oil Seal-output shaft bearing cage

1

143 Deflector-output flange/yoke

1

144 Flange/Yoke-output shaft

1

145 Washer-output shaft

1

146 Nut-output shaft

1

T-2111 SERIES 5450 LB-FT DECLUTCH/P.T.O.

147 Nut-declutch shaft

1

148 Washer-declutch shaft

1

149 Flange/Yoke-declutch

1

150 Deflector-output flange/yoke

1

151 Capscrew-declutch shift cover

4

152 Washer-shift cover capscrew

4

153 Cover-declutch cage

1

154 Quad Ring-declutch piston

1

155 Piston-declutch

1

156 Spring-declutch piston return

1

156A Washer-cage capscrew

1

157 Fork-declutch

1

157A Nipple

1

158 Setscrew-declutch fork

1

159 Washer-declutch plate capscrew

4

160 Capscrew-declutch plate

4

161 Switch Assy.-declutch shift

1

162 Plate-declutch

1

163 Shaft-declutch

1

164 Cage-declutch bearing

1

165 Washer-declutch cage capscrew

8

166 Capscrew-declutch bearing cage

8

167 Bearing-declutch shaft ball

1

168 Snap Ring-declutch bearing

1

169 Oil Seal Assy.-declutch cage

1

170 Oil Seal Assy.-declutch cage

1

T-2111 SERIES 11,000 LB-FT DECLUTCH/P.T.O.

171 Shaft-declutch

2

172 Collar-clutch

2

173 Needle Bearing-declutch shaft

2

174 Shaft Assy.-declutch 

2

175 Switch Assy.-declutch shift

2

175A Washer-declutch plate

1

175B Plug-declutch plate

1

176 Capscrew-declutch plate

8

177 Washer-declutch plate capscrew

8

178 Plate-declutch

2

179 Setscrew-declutch fork

2

180 Fork-declutch

2

181 Plug-declutch cage

2

182 Quad Ring-declutch piston

2

183 Piston-declutch

2

184 Quad Ring-declutch piston

2

185 Spring-declutch piston return

2

186 Cover-declutch cage

2

187 Washer-shift cover capscrew

8

188 Capscrew-declutch shift cover

8

189 Switch Assy.-declutch shift

2

190 Cage-declutch bearing

2

191 Washer-declutch cage capscrew

16

192 Capscrew-declutch brg. cage

16

193 Bearing-declutch shaft ball

2

194 Snap Ring-declutch bearing

2

195 Oil Seal Assy.-declutch cage

2

196 Oil Seal Assy.-declutch cage

2

197 Deflector-declutch yoke

2

198 Flange/Yoke-declutch

1

199 Washer-declutch shaft

2

200 Nut-declutch shaft

2

T-2111 SERIES OIL PUMP

201 Fitting/Filter Assy.

1

202 Fitting-inlet tube to filter

1

203 Button-pump drive

1

204 Coupling-oil pump

1

205 Pump Assy-oil

1

206 Washer-oil pump to cage capscrew

4

207 Capscrew-oil pump to idler cage

4

208 Fitting-oil pump Assy.

1

209 Tube Assy.-lube outlet

1

209A Clamp

2

210 Fitting-outlet tube to cage

1

211 Fitting-oil pump Assy.

1

212 Tube Assy.-lube inlet

1

213 Cage-bearing transfer case

1

214 Washer-cage capscrew

1

215 Capscrew

1

216 Cage-bearing transfer case

1

217 Washer-cage capscrew

1

218 Capscrew-output bearing shaft

4

Item

Description

Qty

Item

Description

Qty

Item

Description

Qty

Pro Gear and Transmission  • 906 W. Gore St. Orlando, FL 32805 • 1 (877) 776-4600 / (407) 872-1901 • [email protected]

Summary of Contents for T-2111 Series

Page 1: ...ent contact your Meritor Fabco replacement part specialists at Pro Gear and Transmission Pro Gear Transmission has same day shipping and 1000 s of products in stock and ready to ship internationally f...

Page 2: ...Maintenance Manual No 3D Revised 2 96 T 2111 D T 2111 SD T 2111 PD T 2111 SPD T 2111 T T 2111 ST T 2111 HP T 2111 SHP MERITOR Pro Gear and Transmission 906 W Gore St Orlando FL 32805 1 877 776 4600 40...

Page 3: ...to equipment or components can occur Serious personal injury can also occur in addition to damaged or malfunctioning equipment or components TORQUE This symbol is used to indicate fasteners that must...

Page 4: ...147 148 149 150 151 152 153 154 155 156 157 164 165 166 167 168 169 170 158 159 160 161 162 163 77 76 75 74 73 129 130 131 132 133 134 135 103 105 104 72C DECLUTCH P T O DECLUTCH OIL PUMP ASE 72B 72A...

Page 5: ...bearing cage 8 112 Nut output shaft 1 113 Washer output shaft 1 114 Flange Yoke output shaft 1 114A Deflector output shaft 1 115 Oil Seal output shaft 1 115A Oil Seal output shaft bearing cage 1 116...

Page 6: ...from Housing 14 Disassemble Idler Gear Input and Output Shaft Assemblies 14 Disassemble Input and Idler Shaft Bearing Cages 14 4 Cleaning and Inspection Clean Ground and Polished Parts 15 Clean Rough...

Page 7: ...2 Declutch Indicator Not Functioning 32 Premature Gear Bearing Wear 32 8 Specifications T 2111 D SD T 2111 PD SPD T 2111 T ST T 2111 HP SHP Specifications 33 Allowable Maximum Speed 33 Transfer Case O...

Page 8: ...latory Guidance References to OSHA NIOSH MSHA and EPA which are regulatory agencies in the United States are made to provide further guidance to employers and workers employed within the United States...

Page 9: ...l Rockwell transfer case air actuated Front Axle Declutch Proportional Differential PD and Full Torque PTO Lockups options are driver controlled from the cab By activating an air plunger or electric s...

Page 10: ...nd 11 000 lb ft 14900 N m capacities CAUTION Continuous use of the axle declutch and proportional differential on good operating surfaces will damage the transfer case PD option transfer cases permit...

Page 11: ...rive is turning Engaging the device during these conditions can cause damage to the transfer case 4 Always monitor the optional engaged disengaged indicator lights Do not operate the vehicle until the...

Page 12: ...n a number designation Assembly designed with 5 450 ft lb 7400 N m rated components Absence of A designation indicates use of 11 000 lb ft 14900 N m components Other alphanumeric characters denote con...

Page 13: ...the differential lockout or the declutch PTO 8 Disconnect the harness for the indicator switch wires 9 Use a hydraulic roller jack to support the transfer case Remove the mounting bolts that hold the...

Page 14: ...ation and serious personal injury Do not reuse lubricant Used lubricant can be contaminated and can cause damage incorrect operation and serious personal injury 2 Remove the drain plug from the bottom...

Page 15: ...arking brake 5 Use a brake shoe return spring removal tool to remove the brake shoe return springs 3 from the ends of the brake shoes 7 Discard the springs and replace them with new springs at reassem...

Page 16: ...t 6 Remove the snap ring from the rear output shaft Remove the planetary spider assembly and spacer Disassemble Planetary Spider Assembly 1 Remove the snap ring from the ends of the planet shafts 2 Re...

Page 17: ...tch mark the bearing cages and transfer case housing so that they can be put together in the same position at reassembly Figure 10 2 Remove the capscrews and washers that attach the bearing cages to t...

Page 18: ...2 If the declutch assembly has a declutch indicator switch remove the declutch indicator switch from the shift plate 3 Remove the capscrews and washers from the declutch shift plate Remove the plate...

Page 19: ...nd shaft assembly from the housing If there are any shims in between the transfer case housing and bearing cage keep them You will use these shims at assembly Replace damaged or worn shims 12 Remove t...

Page 20: ...the bearing cages from the housing NOTE There are no shims under the bearing cages on this side of the housing Section 3 Disassembly Disassemble Idler Gear Input and Output Shaft Assemblies 1 Use a be...

Page 21: ...r in a hot solution tank with a weak alkaline solution 2 Parts must remain in hot solution tanks until completely cleaned and heated 3 Remove the parts from the hot solution and wash them with water u...

Page 22: ...worn level with or below the outer surface B The radius at the large diameters end of the rollers is worn to a sharp edge Figure 16 E Bright wear marks appear on the outer surface of the roller cage F...

Page 23: ...declutch teeth and shift for grooves Replace worn cracked or damaged collars B Inspect the collar pads of the shift fork for wear If the pads are worn replace the shift fork C Inspect the declutch sh...

Page 24: ...line 2 Turn the shafts over and assemble the gears on the shafts The drive gear has a loose fit with the shaft splines and should slip on to the shaft The driven gear has a crossover fit to the shaft...

Page 25: ...of silicone gasket material around the mounting surface of the input bearing cage on the housing Also apply the gasket material around the edge of all the fastener holes Figure 23 See complete instruc...

Page 26: ...isassembly 4 Fasten the bearing cage to the housing with two capscrews 180 degrees apart 5 Tighten the two capscrews to 30 lb in 3 4 N m while rotating one of the shafts in both directions Figure 27 A...

Page 27: ...0 060 in 1 524 mm Average Gap 0 030 in 0 762 mm 0 008 in 0 203 mm Total Shim Pack 0 038 in 0 965 mm NOTE Use a minimum of three shims in a pack If the shim pack is made from different thickness shims...

Page 28: ...d play that exists with the initial shim stack c Subtract the appropriate shim quantity and thickness to close the end plays to within the specified limits Example 0 058 in 1 473 mm Preliminary end pl...

Page 29: ...ollar 9 Install a new quad seal in the declutch piston Make sure that the seal is not twisted 10 Coat the O D of the seal and the bore of the piston in the output cage with a light film of oil 11 Inst...

Page 30: ...event irritation to eyes and skin Wash after skin contact If the Permatex gets in eyes flush the eyes with water for 15 minutes Have eyes checked by a doctor 2 Apply a small amount of Permatex to the...

Page 31: ...put shaft 8 Fit the bearing cage over the shaft 9 Install the two bearing spacers 10 Press the remaining bearing cone in place Check Bearing End Play The rear output bearing end play is controlled by...

Page 32: ...n 12 243 mm 2203 Y 9853 0 490 in 12 446 mm 2203 Z 9854 0 498 in 12 649 mm 2203 A 9855 0 506 in 12 852 mm 2203 B 9856 0 510 in 12 954 mm 7 Remove the yoke nut and yoke then remove the bearing cage outp...

Page 33: ...and washers Tighten the capscrews to 60 75 lb ft 81 102 N m Assemble Parking Brake 1 Install a new seal into the brake adapter with the correct size driver Make sure that the seal is flat in the bore...

Page 34: ...prings 3 on one end of the two brake shoes 7 8 Install the brake shoes in the same position as marked at disassembly with the web ends in position on the backing plate bosses 9 Install the actuator st...

Page 35: ...erial will be applied Remove all oil grease dirt and moisture 3 Dry both surfaces CAUTION The amount of silicone gasket material applied MUST NOT exceed a 0 125 inch 3 18 mm diameter bead Too much gas...

Page 36: ...r the cause of overheating Oil Substitutes CAUTION Rockwell does not approve the use of multi viscosity motor oils Multi viscosity API GL 1 oils within the recommended viscosity range are acceptable b...

Page 37: ...case construction and orientation within the vehicle The actual amount of oil may be substantially different from that shown in Figure 36 For specific duty transfer cases Rockwell may vary oil level r...

Page 38: ...als damaged at installation 2 Yoke journal surface defect or grind lead 3 Seals damaged from overheating 1 Excessive driveline angles balance wear 2 T Case mounting location method 3 Engine torsional...

Page 39: ...well Off Highway Engineering Department Approved ratings may be higher or lower than indicated above dependent upon engineering review GVW RATING TYPICAL 80 000 lbs 36 288 kg Based on 15 x 22 5 Tire a...

Page 40: ...rature Petroleum GL 1 Oil A P I GL 1 90 Above 10 F 12 C with Rust and 80 Above 15 F 26 C Oxidation Inhibitor Heavy Duty A P I CD MIL L 2104B 40 Above 10 12 C Engine Oil CE SF SG G D E 50 Above 10 12 C...

Page 41: ...8474 N m 16 NYS and TYS 7 100 9626 N m 17 NYS and TYS 9 600 13016 N m 176 NYS and TYS 16 000 21693 N m 18 NYS and TYS 21 000 28472 N m 3WCS 3WCS 8 BOLT 5 WCS 12 BOLT Driveline Length Guideline Smalles...

Page 42: ...ate 6 Drain and Fill Plugs 35 lb ft 47 N m Minimum Capscrews 180 230 lb ft 244 312 N m 7 Set Screws 15 20 lb in 1 6 2 2 N m 3 Diff Cover Capscrews 60 75 lb ft 87 102 N m 8 Declutch Piston and 4 Yoke N...

Page 43: ...output declutched in this condition This calculation is mainly for transfer cases which include a differential MismatchHI TRPMR Revs Per Mile of Rear Tires TRPMF Revs Per Mile of Front Tires Page 37 S...

Page 44: ...PD T 2111 HP ALSO USED ON MODELS T 2111 SD T 2111 SPD T 2111 SHP ALSO USED ON MODELS T 2111 SD T 2111 SPD T 2111 SHP 2 T 2111 SHORT DROP CASE WITH OFFSET ORIENTATION T 2111 ST THRU DRIVE MODEL SHOWN...

Page 45: ...and T 2111 Series Transfer Cases This catalog is available from Meritor Literature Distribution Center c o Vispac Inc 35000 Industrial Road Livonia MI 48150 Or call 800 535 5560 Pro Gear and Transmis...

Page 46: ...Etienne S A 2135 West Maple Road Av Jo o Batista 824 4 rue Jean Servanton Troy MI 48084 U S A 06097 900 Osasco SP BP 656 D 3 o N l a u n a M e c n a n e t n i a M 1 x e d e C e n n e i t E t S 2 4 0 2...

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