Copyright Meritor, Inc., 2022
MM-0861 / Revised 06-22
Page 55
Printed in USA
6 Prepare Parts for Assembly
• The rollers and surfaces of the cup and cone inner race
touching the rollers are damaged.
1003020a
ETCHING AND PITTING
Figure 6.4
• The cup and cone inner race surfaces touching the roller
are damaged.
1003021b
SPALLING AND
FLAKING
Figure 6.5
Other Components
• Inspect the gears for wear or damage. Replace worn or
damaged gears.
• Inspect the housing:
• Remove all dirt from the housing and oil lubrication
passages, troughs, slots, and holes.
• Inspect machined surfaces for cracks and damage. Repair
or replace damaged parts.
• Inspect all shafts, flanges and yokes for wear, stress, and cracks
at the splines, shaft, and yoke ears. Replace worn or cracked
shafts, flanges, and yokes.
• Verify oil passages in the shafts are clean and free of debris.
• Inspect the declutch and output shaft components, if applicable:
• Inspect the clutch collar internal splines, external declutch
teeth and shift for grooves. Replace worn, cracked, or
damaged collars.
• Inspect the collar pads of the shift fork for wear. If the pads
are worn, replace the shift fork.
• Inspect the declutch shaft and yoke for wear, stress and
cracks at the splines, shaft and yoke ears. Replace worn or
cracked shafts and yokes.
• Inspect the declutch or PTO push rod and piston for wear or
damage. Replace worn or damaged parts.
• Inspect the rotor, housing, and idler of the oil pump, if equipped,
for scoring. Inspect the drive tab of the rotor assembly. Inspect
the splines on the pump inner rotor for cracks along the spline
area. Also, check for excessive wear. Replace the pump if these
conditions exist.
• Remove and inspect the plug at the end of the input shaft. Verify
the orifice is clear of debris.
Repair or Replace Parts
DANGER
Replace damaged or out-of-specification axle components. NEVER
bend, repair, or recondition axle components by welding or heat
treating. A bent axle beam reduces axle strength, affects vehicle
operation, and voids Meritor’s warranty. Death or serious personal
injury and damage to components can result.
Replace worn or damaged parts of a transfer case assembly.
The following are some conditions to check:
• Replace the fasteners if the corners of the head are worn.
• Replace damaged washers.
• Replace the gaskets, oil seals, grease seals or felt seals at
the time of transfer case repair.
• Clean the parts. Apply new silicone gasket material, where
required, when the transfer case is assembled.
• Use a fine file, emery cloth or crocus cloth to remove rough
edges from parts that have machined or ground surfaces.
• Clean and repair fastener threads and holes. Use a die or
tap of the correct size or a fine file.
• Verify the threads are clean and not damaged, so the
correct torque specifications for fasteners can be obtained.
• Tighten all fasteners to the correct torque specifications.
