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Page 32

Section 7
Diagnostics

Diagnostics:T-2111 Series Transfer Cases

Problem

Overheating

Oil blowing out of breather

Oil seal leaks

Noise / Vibration

Declutch indicator light not functioning

Premature gear/bearing wear

Possible Cause

1. Excess lube quantity

2. Incorrect lube viscosity

3. Excessive speed (RPM)

4. Excessive axle ratio (Tire size mismatch)

1. Excessive speed (RPM)

2. Excess lube quantity

3. Unusual mounting orientation

4. Incorrect lube

5. Incorrect breather location

1. Seals 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 acceleration not damped

4. Excessive T-case bearing end play

5. Operating on good surface with declutch engaged

1. Damaged switch or declutch unit

2. Inadequate air pressure

3. Defective piston seal

4. Bulb burned out

1. Contaminated or inadequate quantity of lube

2. Incorrect bearing adjustment

3. Excessive axle ratio/tire size mismatch

4. Excessive PD or front declutch lock up

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

Содержание T-2111 Series

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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