Meritor MTC 4208 4210 4213 Transfer Case MM-0146
Meritor MTC 4208 4210 4213 Transfer Case MM-0146
Meritor MTC 4208 4210 4213 Transfer Case MM-0146
Transfer Cases
MTC-4208, -4210 and -4213
Revised 12-08
Service Notes
CAUTION
A Caution alerts you to an instruction or procedure that you
must follow exactly to avoid damage to components.
Information contained in this publication was in effect at the time the publication was
approved for printing and is subject to change without notice or liability. Meritor Heavy
Vehicle Systems, LLC, reserves the right to revise the information presented or to
discontinue the production of parts described at any time.
pg. 1 Section 1: Exploded Views pg. 34 Input Bearing Cage and Oil Pump Assembly Installation,
MTC-4208 Transfer Case Rear Cover Bearing End Play Adjustment and Transfer Case Final
MTC-4208 Transfer Case Front Case Assembly
2 MTC-4210 Transfer Case Rear Cover 35 Transfer Case Shifting Check
3 MTC-4210 Transfer Case Front Case 36 Adjust the Oil Level
4 MTC-4213 Transfer Case Rear Cover Transfer Case Assembly Test
5 MTC-4213 Transfer Case Front Case 37 Section 7: Power Take-Off (PTO)
6 MTC-4208 and -4210 Declutch/PTO Installation
7 Section 2: Introduction 39 Remove the Transfer Case Rear Access Cover
Model Nomenclature 40 Install the Yoke Onto the PTO
Meritor Transfer Case Model Nomenclature Install the Optional Indicator Switch
8 Description 41 Install the PTO Onto the Transfer Case
9 Operation Test the PTO Installation
Front Axle Declutch (If Equipped) 42 Test the Transfer Case with the PTO Assembly Installed
10 Oil Cooler Option PTO Assembly
Blow-by Breather 45 Section 8: Installation
11 Full-Torque Power Take-Off (PTO) Install the Transfer Case
Breather Location Check and Adjust the Oil Level
12 Section 3: Removal 46 Section 9: Diagnostics
Remove the Transfer Case Assembly Troubleshooting
14 Section 4: Disassembly Transfer Case Lubrication Diagnostics
Disassemble the Transfer Case 48 Excessive Noise and Vibration Diagnostics
Front and Rear Output Yokes 49 PTO Does Not Engage/Disengage Diagnostics
Front Input Shaft, Input Bearing Cage and Pump Assembly 50 Front Axle Declutch Does Not Engage/Disengage
17 Front Input Shaft, Input Shaft Bearing Cage and Oil Pump Diagnostics
18 Idler Gear Shaft 51 High/Low Gear Shifting Diagnostics
Optional PTO Assembly on MTC-4208 and -4210 Transfer 52 Section 10: Lubrication and Maintenance
Cases How to Obtain Additional Lubrication and Maintenance
19 Section 5: Prepare Parts for Assembly Information
Clean, Dry and Inspect Parts Lubricant Temperatures
Ground and Polished Parts Meritor MTC-4208, MTC-4209 and MTC-4210
Parts with a Rough Finish Series Transfer Cases
Transfer Case Assemblies Do Not Install API GL-5 Oils
Dry Cleaned Parts Petroleum-Base and Multi-Viscosity Oils
Prevent Corrosion Operating Information
20 Inspect Parts Magnets and Magnetic Drain Plugs
23 Preparing the Case and Cover and Seal Replacement Breather
53 Seals
24 Section 6: Assembly Special Tools and Installation Procedure
Assemble the Transfer Case 54 Check and Adjust the Oil Level
26 Adjustment Drain and Replace the Oil
MTC-4213 Rear Output Shaft End Play 55 Inspection
MTC-4208 and -4210 Rear Output Shaft End Play Meritor MTC-4208, -4210 and -4213 Transfer Case
27 Idler Shaft Bearing End Play Inspection
28 Front Output Shaft End Play
29 Assembly 57 Section 11: Specifications
High and Low Shifter Torque Specifications
30 Front Axle Shifter 58 Section 12: Vehicle Towing Instructions
31 Front Input Shaft, Input Shaft Bearing Cage and Oil Pump Guidelines
Assembly
32 Input Seal Installation 59 Section 13: Special Tools
Tool Drawing
1 Exploded Views
Figure 1.1
15
14
1 15
6 13
12
11A
13
9 11 1
10
8 16
23
7 13
6 1
13
5
1 3
21
4
2
17 59
18 37
19 46 1
20
3 4000181b
Item Description Item Description
1 Capscrew and Washer 19 Rear Output Yoke
2 Cover 20 Flat Washer
3 Locknut 21 Optional PTO Assembly
4 Hardened Washer 22 Driven Gear and Rear Output Shaft
5 Transfer Case Rear Cover 23 Snap Ring
6 Shipping Protector 24 Shift Shaft
7 Shift Cylinder 25 Input Shaft
8 Shift Piston O-Ring 26 Special Orifice Plug
9 Shift Piston 27 Shift Fork Capscrew
10 O-Ring 28 Shift Fork
11 Neutral Breather* 29 Helical Drive Gear, High Range
11A Blow-by Breather 30 High and Low Clutch Collar
12 Speed Sensor 31 Helical Drive Gear, Low Range
13 Bearing Cup 32 Snap Ring
14 Idler Gear 33 Transfer Case Front Case
15 Bearing Cone * Vehicles not equipped with a transfer case neutral air control may be
16 Ceramic Magnet equipped with a neutral breather which allows the shift cavity to
17 Switch Assembly exhaust. On vehicles equipped with a neutral air control, the solenoid
18 Rear Output Oil Seal allows this cavity to exhaust.
59 41 3
40
44 20
38 61
7 39 35 36 15
42
34
43
33
47
6
8 32
9 31 3
48 45
30 20
28 29 49
24 50
27
17 60
9 13
10 51
26 25
63
15 53
15 13
62
23 40
10 22
10 36
15
56
57
52
15
35
58 28
54
33
43 51
4000181a
Item Description Item Description
34 Locating Dowel Pin 49 Front Output Yoke
35 Inlet Oil Tube Assembly 50 Front Output Oil Seal
36 Male Fitting 51 Drain Plug
37 Breather Assembly 52 Push Rod
38 Oil Pump Assembly 53 Locating Dowel Pin
39 Relief Valve Spring 54 Front Output Clutch Collar
40 Input Bearing Cage 55 Spring
41 Bearing Cage Capscrew and Washer 56 Front Output Shaft
42 Input Oil Seal 57 Helical Driven Gear
43 Oil Fitting Assembly 58 Locknut and Flat Washer
44 Relief Valve 59 Shim
45 Oil Pump Capscrew and Washer 60 Plug
46 Elbow 61 Input Yoke
47 Oil Fill Plug 62 Oil Cooler Male Connector
48 3/8-Inch Plug 63 Loop Tube
15
14
1 15
6 13
12
11A
13
9 11 1
10
8 16
23
7 13
6 1
13
5
1 3
21
4
2
17 59
18 37
19 46 1
20
3 4005178b
Item Description Item Description
1 Capscrew and Washer 19 Rear Output Yoke
2 Cover 20 Flat Washer
3 Locknut 21 Optional PTO Assembly
4 Hardened Washer 22 Driven Gear and Rear Output Shaft
5 Transfer Case Rear Cover 23 Snap Ring
6 Shipping Protector 24 Shift Shaft
7 Shift Cylinder 25 Input Shaft
8 Shift Piston O-Ring 26 Special Orifice Plug
9 Shift Piston 27 Shift Fork Capscrew
10 O-Ring 28 Shift Fork
11 Neutral Breather* 29 Helical Drive Gear, High Range
11A Blow-by Breather 30 High and Low Clutch Collar
12 Speed Sensor 31 Helical Drive Gear, Low Range
13 Bearing Cup 32 Snap Ring
14 Idler Gear 33 Transfer Case Front Case
15 Bearing Cone * Vehicles not equipped with a transfer case neutral air control may be
16 Ceramic Magnet equipped with a neutral breather which allows the shift cavity to
17 Switch Assembly exhaust. On vehicles equipped with a neutral air control, the solenoid
18 Rear Output Oil Seal allows this cavity to exhaust.
59 41 3
40
44 20
38 61
7 39 35 36 15
42
34
43
33
47
6
8 32
9 31 3
48 45
30 20
28 29 49
24 50
27
13 17
9 10
26 51
25 60
15
15 13 53
63
23
10 22 62
10 40
15
36 33
56
57
52
15
58 28
54
35
58 55 43 51
25
10 22 26
13
4 4 27 28
5A
4 5 6 24
8 12 13 57
8 7 16 23
14
3 4
2
9
1 11
12
30
21
57 31
14 12
12 57 57
11 12
13
20 34
19 18
57
59 17 56
4000180b
39
61
60 58 36
44 36
1 12
35
56
2 37
48 33
32 43 11
38
45
41
46 31
40
47
29
57
37
12 11
42
15
12 49
57 53 5
56 51 18
52
54 64
63
62 57 35
30
12 33
12
11 50
37 55
32
29
40 47
13 10
9
16
8
7
6
15
18
17
12 11
5
4
1
19
14 4000182a
8 O-Ring
9 Cover Plate
10 Capscrew
11 Shifter Spring
12 Cap
Model Nomenclature
2 Introduction
Housing
Number Material Specification
Transfer Case of Speeds G= Grey Iron Number Low Ratio
1 = Single Speed D = Ductile Iron
2 = Two Speed A = Aluminum
Figure 2.2
Description
Meritor MTC-4208, -4210 and -4213 transfer cases are four-shaft
designs with two-speed front and rear output having a 1:1 and a
1:2.05 ratio for use with 4x4 and 6x6 vehicles. The MTC-4208 and
-4210 are designed specifically for use in 4x4 vehicles (the
MTC-4213 is designed specifically for 6x6) as part of the Meritor
medium-duty 4x4 system. Figure 2.1.
Figure 2.1
4000185a
The air-actuated front-axle declutch (if equipped), high and low Figure 2.2
shifter and full-torque power take-off (PTO) lockup are controlled NEUTRAL PORT
(MTC-4208 AND HIGH
from the cab. An air plunger or electric switch, usually mounted on LOW RANGE
-4210 ONLY)
the instrument panel, engages or disengages a mechanical clutch. RANGE PORT
PORT
An optional speed sensor measures transfer case output driveline
rpm. Optional switches indicate when the front axle declutch is fully
engaged or disengaged.
These transfer cases provide for two-speed output (high range and
low range) and a neutral position that is used for PTO-equipped
transfer cases only. Non-PTO cases have this neutral position
plugged. Figure 2.2.
4000186a
Figure 2.2
The front axle declutch permits shifting from part-time 4x4 or 6x6 to Figure 2.4
Figure 2.3
HIGH
LOW RANGE INPUT PTO
RANGE GEAR SHAFT OUTPUT
GEAR SHAFT
DOUBLE REAR
IDLER GEAR OUTPUT
SHAFT SHAFT
REAR
INPUT
OUTPUT
SHAFT
SHAFT
DOUBLE IDLER
GEAR SHAFT SINGLE
IDLER GEAR
SHAFT
FRONT
DECLUTCH
PUSH
ROD AND MTC-4213 FRONT
SHIFT FORK OUTPUT 4000184a
SHAFT
Figure 2.4
Operation
Front Axle Declutch (If Equipped)
FRONT
OUTPUT
WARNING
SHAFT 4000183a Do not engage the front axle declutch when the vehicles
wheels are slipping or when moving up or down a steep hill or
Figure 2.3
grade, which can cause the vehicle to lose stability. Serious
personal injury and damage to components can result.
Shift the transfer case into low from high gear or from high to low Oil Cooler Option
gear when the vehicle is stationary. Apply the parking brake with the
Vehicle configuration can have a significant impact on MTC model
transmission in Neutral, automatic transmission only.
transfer cases. Vehicles with overdrive transmissions used primarily
You will know that engagement occurs by hearing it, noticing for high-speed highway routes run at higher transfer case input
improved vehicle performance, or observing the optional indicator speeds. Transfer case running temperature is primarily affected by
light in the cab. input speed, regardless of rear-wheel-drive only or 4x4/6x6 operation.
If the clutch does not fully engage: Turn the steering wheel in A transfer case oil cooler reduces operating temperatures which will
one direction and rock the vehicle back and forth until improve yoke seal life, reduce oil degradation and reduce the
engagement occurs. likelihood for other oil and air leaks. Figure 2.5.
Figure 2.5
FRONT
4005169a
Figure 2.5
An oil cooler may be adaptable to MTC transfer cases with the Blow-by Breather
following designation in the product specification. Product
information can be found on the transfer case nameplate located on The rear cover portion of the housing on models built fall of 2004
forward is equipped with a blow-by breather. The breather, which
the front of its housing.
points sideways on the driver side of the housing, prohibits
Part number MTC-4210-GCS-100-100-205 where the C pressurization of the housing if an O-ring becomes damaged.
stands for Cooler Ready Because all range shifts require full time pressurization, a damaged
Part number MTC-4210-GS-100-100-205 is not cooler ready. O-ring would allow air to fill the housing which could further damage
the yoke seals or blow oil from the housing.
The reconfiguration provides the means to divert oil from the
transfer case pump out to an oil cooler and return to the shaft oil
gallery. A loop line may be used on models that have cooler
capability yet do not have an oil cooler connected. Refer to Technical
Publication TP-0468, Connecting an Oil Cooler to MTC-4208,
-4210 and -4213 Transfer Cases, for further instruction on
connecting an oil cooler.
Breather Location
On older transfer case models, the breather assembly was located
on the front case. On current transfer case models, the breather
assembly is located on the rear cover. Figure 2.6.
If the breather is found in either of the old positions, it is
recommended that the breather be repositioned.
Figure 2.6
OLD
BREATHER
POSITIONS
NEW
BREATHER
POSITION
4004223a
FRONT CASE REAR COVER
Figure 2.6
Hazard Alert Messages 6. Disconnect the air lines at the shift cylinders of the transfer
3 Removal
case.
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent 7. Disconnect the harness for the indicator switch wires.
serious personal injury, damage to components, or both. 8. Use a hydraulic roller jack to support the transfer case. Remove
the mounting bolts that hold the transfer case to the vehicle.
WARNING
9. Carefully remove the transfer case with the hydraulic jack.
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
CAUTION
Park the vehicle on a level surface. Block the wheels to Close or cover all openings, including the breather, oil drain
prevent the vehicle from moving. Support the vehicle with and speed sensor, before steam cleaning the outside of the
safety stands. Do not work under a vehicle supported only by transfer case. Steam can damage components.
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result. 10. Close or cover all openings before steam cleaning. These
openings include the breather, oil drain and speed sensor.
Remove the Transfer Case Assembly 11. Steam clean the outside of the transfer case to remove heavy
amounts of dirt.
1. Park the vehicle on a level surface. Place blocks under the
wheels not being raised to keep the vehicle from moving. 12. Construct angle iron brackets or similar fixtures. Attach the
brackets to the front half of the transfer case by installing bolts
2. Raise the vehicle so that the area to be serviced is off the
through the mounting holes in the transfer case. Figure 3.2.
ground. Support the vehicle with safety stands.
3. Place a large container under the transfer case. Figure 3.2
Figure 3.1
FRONT INPUT
OUTPUT POSITION
POSITION
MOUNTING MOUNTING
HOLES HOLES
INLET
OIL
4000187b
TUBE
OIL Figure 3.2
FILL
PLUG
MAGNETIC
DRAIN
PLUG STANDARD MODEL SHOWN
FRONT COVER 4000189a
Figure 3.1
Figure 3.3
NOTE: The transfer case weighs approximately 670 lbs (304.2 kg)
without the PTO.
LIFTING
HOLE 14. Attach a suitable lifting device to the eye-bolts to lift the
FRONT
transfer case. Use the angle iron brackets to mount the case in
CASE the repair stand. Figure 3.2.
LIFTING
HOLE
REAR
COVER
4000188a
Figure 3.3
Figure 4.1
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent FRONT
VIEW
serious personal injury, damage to components, or both.
INLET
OIL
WARNING TUBE
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
2. Remove the yoke locknuts and washers from the front and rear Figure 4.1
output shafts.
2. Remove the capscrews securing the input bearing cage and
3. Use a yoke puller to remove the yokes from the output shafts. pump assembly.
Do not remove the deflector from the yoke or flange unless it is
damaged. NOTE: The high- and low-range clutch collar becomes loose on the
4. Loosen but do not remove the front input yoke, locknut and shift fork as the input bearing cage and pump assembly is removed
washer from the front input shaft, input bearing cage and and may drop into the case. Shifting the transfer case into high
pump assembly. The yoke is used to lift the assembly from the range keeps the shift collar on the high-range gear, which keeps it
transfer case. in place. Also, shifting into high range allows easier rear cover
removal on the MTC-4208 and -4210 transfer cases.
5. MTC-4208 and -4210 transfer cases only: Remove the rear
input shaft cover capscrews and rear cover, or PTO, if 3. Shift the transfer case into high range using compressed air at
equipped, from the rear transfer case cover. Refer to the the high-range port of the shift cylinder. Figure 4.2 and
procedure in this section. Figure 2.2.
6. MTC-4208 and -4210 transfer cases only: Use a modified
3/4-inch drive three-inch socket to remove the large
Figure 4.2
BLOW-BY
Front Input Shaft, Input Bearing Cage and BREATHER
(IF EQUIPPED)
Pump Assembly
NEUTRAL PORT
1. Remove the inlet oil tube from the transfer case by loosening HIGH RANGE (PTO-EQUIPPED ONLY)
the fittings at the lower front case and input-bearing cage. PORT
4000191c
Figure 4.1.
Figure 4.2
4. With the front input yoke still installed, remove the yoke, input Figure 4.5
Figure 4.3
FRONT OUTER
VIEW SHIFT
PISTON
4000192a
Figure 4.5
Figure 4.3
D. Remove the inner shift piston snap ring from the shift Figure 4.6
shaft. Remove the shift piston. Figure 4.6.
Figure 4.4
6. Use the following procedure to separate the case halves.
NEUTRAL PORT A. Remove the capscrews securing the rear cover to the
(MTC-4208 AND HIGH
LOW
-4210 ONLY) RANGE front case.
RANGE PORT
PORT B. Use a pry bar to separate the two halves of the transfer
case at the pry tab locations around the case.
C. Place eye-bolts into the rear cover lift holes located at the
top and bottom of the cover.
D. Attach a suitable lifting device to the eye-bolts. Lift the
rear cover from the front case.
E. As the rear cover is lifted, verify that the high and low shift
shaft remains in the case by placing pressure on the shaft
while separating the transfer case halves.
F. The rear output shaft and high-range gear are removed as
4000186a an assembly along with the rear cover on MTC-4213
Figure 4.4
transfer cases only. The shaft is pressed into the bearing
assembly which keeps the shaft retained in the housing.
Figure 4.7
Use a chain and suitable lifting device to secure the rear cover
in the press to prevent serious personal injury and damage to
DOUBLE-GEAR
IDLER SHAFT components.
11. Set the rear cover with the rear output shaft as an assembly
into a suitable press. Figure 4.9.
HIGH AND LOW
SHIFT FORK AND
SHAFT ASSEMBLY Figure 4.9
4000194c
Figure 4.7
Figure 4.8
Figure 4.9
WARNING
The rear output shaft assembly is heavy. Support the assembly
to prevent it from dropping during the pressing operation.
Serious personal injury and damage to components can result.
12. Press the rear output shaft assembly out of the rear cover.
Figure 4.9.
13. Use a suitable puller to remove the rear output shaft outer
bearing cone and cup from the rear cover. Discard the cone
4000195a and cup.
Figure 4.8 14. Inspect the rear output shaft inner bearing cone and cup for
wear or damage. Replace a worn or damaged bearing cone
10. Remove the shift cylinder and push rod from the front case. and cup.
Remove the two locating dowel pins. Note their correct
location.
Figure 4.10
4000199a
MTC-4208
AND MTC-4210 Figure 4.12
4. Remove the spiral snap ring that retains the small helical gear
on the input shaft. Lift the small helical gear off the shaft.
Figure 4.13.
Figure 4.13
4000197a
Figure 4.10
2. Use a yoke puller to remove the front input yoke. Figure 4.11.
Figure 4.11
4000200a
Figure 4.13
3. Lift the front input bearing cage and oil pump assembly off the 7. Mark the position of the pump to the cage for reassembly.
input shaft. Figure 4.12. Figure 4.14.
OIL INLET
PORTS
4000201b
Figure 4.14
8. Match the pump oil inlet to the cage oil inlet. Match the
chamfered relief port in the oil pump with the relief valve and 4000202b
spring assembly in the cage.
Figure 4.15
9. Replace the bearing cone and cup as necessary.
10. Inspect the pump inner rotor in the spline area for cracks or WARNING
other damage. The entire pump must be replaced if the pump Take care when you remove the spring-loaded PTO cap.
or inner gear rotor is damaged in any way. Serious personal injury and damage to components can result.
Idler Gear Shaft 5. Carefully remove the spring-loaded PTO cap by turning each
1. Use a suitable bearing cone puller to remove the bearing cones bolt a few turns at a time until all the bolts can be removed at
as necessary from the single idler-gear shaft, rear output shaft once.
on MTC-4208 and -4210 transfer cases, or double idler-gear 6. Remove the capscrews from the cover of the declutch piston.
shaft assemblies. Remove the cover.
2. Inspect and replace bearing cones with new as needed. 7. Remove the PTO piston push rod and the return spring.
Replace bearing cones and cups as a set. Remove the O-ring seal from the PTO piston.
3. Inspect the shafts and gears for wear or damage. 8. Remove the O-ring seal on the cover. Discard the seal. Remove
the shift fork and clutch collar.
Optional PTO Assembly on MTC-4208 and 9. Remove the oil and dirt seals from the bearing cage assembly.
-4210 Transfer Cases Discard the seals.
1. Rotate the transfer case in the repair stand so that the PTO
10. Press the shaft out of the bearing cage. Remove the bearing
assembly, if so equipped, is facing UPWARD. Figure 4.15.
assembly.
2. Remove the yoke nut, washer and yoke. Use a yoke puller to
11. Remove the bearing cups as a unit with the bearing spacer by
remove the yoke.
pressing the cups out of the bearing cage. Do not separate
3. Remove the PTO indicator switch from the shift plate, if these parts. They are a matched set.
equipped.
4. Remove the cage mounting capscrews and washers from the
PTO. Lift the PTO assembly off the transfer case.
Read and observe all Warning and Caution hazard alert messages in 1. Use a cleaning solvent or a hot solution tank with a weak
this publication. They provide information that can help prevent alkaline solution to clean parts with a rough finish.
serious personal injury, damage to components, or both. 2. Leave the parts in the hot solution tank until they are
completely cleaned and heated. When the parts are clean,
WARNING remove them from the tank.
To prevent serious eye injury, always wear safe eye protection
3. Wash the parts with water until you completely remove the
when you perform vehicle maintenance or service.
alkaline solution.
Clean, Dry and Inspect Parts 4. Clean the three magnets attached to the bottom of the front
case.
Ground and Polished Parts 5. Remove and clean the magnetic drain plug.
Discard all oil seals and O-rings. Replace with new parts.
Inspect Parts
It is very important to inspect all parts carefully and completely WEAR
CRACK
before the transfer case is assembled. Check all parts for wear and GROOVES
stress. Replace all damaged parts.
1. Inspect the tapered roller bearings. Inspect the cup, cone,
rollers and cage of all tapered roller bearings in the assembly.
If any of the following conditions exist, the bearing must be
replaced:
The center of the large diameter end of the rollers is worn
level with or below the outer surface. 1003018b
The radius at the large diameter end of the rollers is worn to Figure 5.2
a sharp edge. Figure 5.1.
A visible roller groove is worn in the inner race surfaces of Figure 5.3
Figure 5.4
Figure 5.1
1003020a
Figure 5.1
Helical Gears
Inspect the helical gear teeth, splines and journals. If any of the
following conditions exist, replace the gear.
SPALLING AND FLAKING A crack in the root of a tooth or along the tooth flank. Figure 5.6.
Severe scoring or fretting on the surface of a tooth. Gears with
scoring and fretting on the teeth, but without cracks, may
continue to operate satisfactorily with higher noise. Figure 5.7.
Cracks along the internal journal of the input gears. Figure 5.8.
1003021b Deep gouges or metal transfer along the input gear journals.
Figure 5.5 Figure 5.9.
Chipped or severely worn shifting splines on the input gears.
2. Inspect the gears for wear or damage. Replace worn or
damaged gears. Chipped or cracked splines on the output gears.
B. Inspect the collar pads of the shift fork for wear. If the SPALLING
pads are worn, replace the shift fork.
C. 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.
D. Inspect the declutch or PTO push rod and piston for wear
or damage. Replace worn or damaged parts.
7. 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.
4000294a
8. Remove and inspect the restrictor plug at the end of the input
shaft. Figure 5.7
Inspect the input and output shafts for damage to the gear journals, METAL
TRANSFER
shifting splines, threads and gear retaining splines. If any of the
following conditions exist, replace the shaft.
Deep gouges or metal transfer along the input shaft journals.
Figure 5.10.
Chipped or worn shifting splines on the input shaft.
Chipped or cracked splines on the output shaft. Figure 5.11.
Cracks along the yoke splines, bearing journal abutments or
cross-drilled holes. Magnaflux may be necessary to see small
cracks. 4000297a
Figure 5.10
Figure 5.8
Figure 5.11
CHIPPED
SPLINES
CRACK
4000295a
Figure 5.8
4000298a
Figure 5.9
Figure 5.11
PTO Components
Inspect the PTO housing, shaft, taper bearings, shift collar, shift fork
and sensors for damage. If any of the following conditions exist,
replace the component.
Cracks in the housing.
Cracks along the shaft yoke spline or ball bearing abutment.
Magnaflux may be necessary to see small cracks.
Chipped or cracked shifting splines on the shift collar or shaft.
4000296a
The rollers of the taper bearings do not roll easily or lack
Figure 5.9 lubrication. The raceway is cracked or dented.
Cracked or missing tangs on the shift fork arms.
The sensor ball sticks or does not return to its resting position.
The sensors do not complete a circuit when tested with a
volt-ohm meter (VOM).
Torn or feathered areas on the O-ring. 3. Clean and inspect the transfer case and cover for cracks, worn
threaded holes or other wear or damage. Clean the gasket
Deep gouges in the shifting bores of the case halves. surfaces of both transfer case halves using a suitable gasket
scraper or wire wheel.
Oil and Lubrication System
4. Press new bearing cups into the case halves as necessary.
The lubrication system is extremely important to the performance of
Refer to Section 6 for bearing setting procedures.
the transfer case. Inspect all parts closely for excessive wear or
damage. Perform the following checks. 5. Inspect the bearing end play to ensure that its within
specification. Adjust the end play, if required. Refer to
1. Inspect the oil for metal shavings, dirt and consistency.
Section 6.
Perform an analysis if the oil appears contaminated.
6. Install new oil seals into the case halves. Use Meritor seal
2. Check the magnets for metal shavings. A small amount of
driver, part number R4422402, for a 3.25-inch nominal
metal shavings is normal. However, excessive build-up
diameter seal. The seal driver is included in Meritor Kit 4454.
indicates gear and bearing damage. Thoroughly remove all
Refer to the Service Notes page on the front inside cover of this
metal shavings from the magnets. The magnets must be firmly
manual to obtain this Kit.
fastened to the case.
3. Check the sump screen. Remove any material that may restrict
oil flow through the mesh.
4. Inspect the seals closely. Look for nicks and tears on all sealing
lips. Any damage is likely to result in a seal leak.
5. Check the pump for easy rotation. If the internal gear does not
spin easily or jams when rotating the crescent plate, replace
the pump.
6. Check the oil line for damage. Replace if it is dented or kinked.
7. Verify that the pump drive pins are 0.063-inch (1.6 mm) above
the diameter of the shaft. Remove and set to the correct
position if necessary.
Hazard Alert Messages 3. Position the clutch collar onto the stamped shift fork. Position
6 Assembly
the shift fork and clutch collar onto the front output shaft clutch
Read and observe all Warning and Caution hazard alert messages in hub.
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both. 4. Install the front output shaft, shift fork and clutch collar over the
front output shaft tapered roller bearing in the front case.
WARNING Figure 6.2.
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service. Figure 6.2
Figure 6.1
4000205a
Figure 6.3
6. Temporarily install the shift cylinder onto the case to secure the
push rod in place.
7. The shift cylinder requires Loctite sealant for final assembly.
8. Install the release spring over the push rod and shift fork.
4000203a
Figure 6.1
9. Install the high and low shift fork and shift shaft into position in 15. Assemble all remaining case-to-cover capscrews upon
the front case. Figure 6.4. achieving the correct end play measurement on all shafts.
Figure 6.4
16. Lubricate and install the O-ring into the rear cover push rod
journal. Use a light coat of lithium-based grease, Meritor
DOUBLE-GEAR
IDLER SHAFT
specification O-688, prior to cover installation. Figure 6.6.
Figure 6.6
NEUTRAL PORT
HIGH AND LOW (MTC-4208 AND HIGH
SHIFT FORK AND LOW -4210 ONLY) RANGE
SHAFT ASSEMBLY RANGE PORT
PORT O-RING
4000194c
Figure 6.4
10. Determine all shaft bearing end plays before final assembly.
Refer to the procedures in this section.
11. Install the two locating dowel pins into the corresponding holes
in the front case.
4000186b
12. Use a suitable lifting device to install the rear cover and output
shaft as an assembly over the front case. Figure 6.5. Guide the Figure 6.6
cover over the shift fork and push rod as the cover is being set
into place over the case. 17. Apply Loctite 518 sealant to the case-to-cover flange.
Apply a 1/8-inch (3 mm) bead of sealant around the entire
Figure 6.5
Figure 6.5
13. Verify that the locating dowel pins have engaged both the case
and the cover and that the cover is fully seated on the case.
14. Secure the case to the cover joint by assembling at least six
equally spaced case-to-cover capscrews.
BEARINGS
4000183b 2" (50.8 MM)
Apply sealant in
Figure 6.7 this area.
4. Use a dial indicator to check output shaft bearing end play. Idler Shaft Bearing End Play
Center the dial indicator over the shaft using a ball bearing for
Determine the idler shaft bearing end play before final assembly.
accuracy. Figure 6.10.
Seals should not be installed until the end plays are set.
Figure 6.10
1. Temporarily install at least six case-to-cover capscrews evenly
spaced around the case.
2. Rotate the transfer case so that the front of the case faces
UPWARD.
3. Remove the 3/8-inch (9.5 mm) pipe plugs at the idler shaft
locations on the front of the case.
4. To prepare to check idler shaft bearing end play, insert a
1/2"-13 bolt into the shaft through the pipe plug hole, until the
bolt is fully seated. The bolt should extend out of the transfer
case enough for you to use it to lift the idler shaft.
4000209a
5. Tighten the bolt so that it bottoms in the shaft for an accurate
end play measurement.
Figure 6.10
6. Rotate the idler shaft several times to help seat the bearing
cones.
5. Use a pry bar to lift the yoke to obtain a measurement.
To obtain a consistent and averaged reading, perform this 7. Set up the dial indicator to check the idler shaft bearing end
operation two or three times. Record the reading for this shaft. play. Center the dial indicator on the bolt head. Zero the
indicator. Figure 6.11.
If the end play reading is greater than
0.001-0.005-inch (0.025-0.127 mm): Add shims to Figure 6.11
to adjust shims and achieve correct the end play on the shaft Figure 6.11
requiring adjustment.
9. Adjust shims to achieve the correct bearing end play on all
shafts as required. Refer to the procedure in this section.
8. Use pry bars to lift up on the bolt head to obtain a 2. Install the front output shaft yoke. Temporarily tighten the yoke
measurement. To obtain a consistent and averaged reading, nut to 200 lb-ft (271 Nm). @
perform this operation two or three times. Record the reading
3. Rotate the output shaft several times to seat the bearings.
for this shaft.
4. Set up a dial indicator to check the output shaft bearing end
If the end play reading is greater than
play. Center the dial indicator over the shaft using a ball
0.001-0.005-inch (0.025-0.127 mm): Add shims to
bearing for accuracy. Figure 6.13.
reduce end play.
If the end play reading is less than specification: Figure 6.13
12. Adjust the shims to achieve the correct bearing end play on all Figure 6.13
shafts as required. Refer to the procedure in this section.
5. Use a pry bar to lift the yoke to obtain a measurement. To
Front Output Shaft End Play obtain a consistent and averaged reading, perform this
Determine the front output shaft bearing end play before final operation two or three times. Record the reading for this shaft.
assembly. Seals should not be installed until the end plays are set. If the end play reading is greater than
1. Before installing the yoke, clean the splines of old silastic. 0.001-0.005-inch (0.025-0.127 mm): Add shims to
Apply a 1/8-inch (3.175 mm) bead of RTV 732 sealant 360 reduce end play.
degrees around the outer two-inches (50.8 mm) of the yoke If the end play reading is less than specification:
splines. Figure 6.12. Remove shims to increase end play. Bearing shims come in
0.003-, 0.005- and 0.010-inch (0.08, 0.13 and 0.25 mm)
Figure 6.12
thicknesses.
2" (50.8 MM)
Apply sealant in If the front output shaft bearing end play requires
this area. adjustment: Remove the front output shaft yoke so that the
case and cover can be easily separated.
6. Measure the end play on the remaining shafts before splitting
the case to make adjustments.
7. After performing the front output shaft bearing end play
measurement, separate the transfer case halves as necessary
to adjust the shims and achieve the correct end play on the
shaft requiring adjustment.
4005171a
8. Adjust the shims to achieve the correct bearing end play on all
Figure 6.12 shafts as required. Refer to the procedure in this section.
Shim Assembly NOTE: Before final assembly, verify that each shim selection
procedure results in the correct end play specification. Repeat the
In order to adjust the end play on any shaft, it is necessary to split
end play measurement steps, as necessary, to obtain the correct
the transfer case.
end play specification on all shafts.
1. Rotate the transfer case in the stand so that the rear cover is
facing UP. Remove the case-to-cover capscrews. 8. Reassemble the cover to the case. Install at least six
case-to-cover capscrews.
2. Use a suitable lift to remove the rear cover. Mount the cover so
that the pressed-in bearing cups can be removed.
Assembly
3. Use a bearing puller to remove the bearing cups from the
cover. Shims are placed between the cover and the cup. Refer High and Low Shifter
to the exploded views in this manual.
1. Grease all O-ring seals. Use a light coat of lithium-based
4. Select the correct shim or shims to achieve the correct end grease, Meritor specification O-688. Refer to Figure 6.14 for
play. If the end play measurement is below 0.001-inch shifter component arrangement.
(0.03 mm), which indicates a pre-loaded shaft, start by
removing shims until some measurable end play is observed. Figure 6.14
NEUTRAL PORT
Table A: Example of shim selection: (MTC-4208 AND HIGH
LOW RANGE
-4210 ONLY)
Initial measurement (idler shaft) 0.018-inch RANGE PORT
PORT
(0.46 mm)
Specification 0.001-0.005-inch
(0.03-0.13 mm)
Required shim stack 0.017-0.013-inch
(0.43-0.33 mm)
Figure 6.15
Front Axle Shifter
1. Rotate the transfer case to install the front axle shift cylinder.
2. Remove the front axle shift cylinder used to temporarily hold
the shift shaft in place.
INNER
SHIFT 3. Grease the O-ring on the piston and install the piston into the
PISTON
cylinder.
4. Apply a 1/8-inch (3 mm) bead of Loctite 277 sealant to the
first three threads of the shift cylinder.
5. Install and tighten the shift cylinder to 85-95 lb-ft
4000193b (115-129 Nm). @
Figure 6.15 6. Install the front output shaft oil seal using oil seal driver
R4422402, Meritor Kit 4454. Drive the seal until it is fully
3. Install O-rings onto the inside diameter and outside diameter of seated. Figure 6.17.
the outer piston. Install the outer shift piston.
Figure 6.17
4. Install the outer shift piston outer snap ring onto the shift shaft.
Figure 6.16.
Figure 6.16
OUTER
SHIFT
PISTON
4000210a
Figure 6.17
7. Install the front output shaft yoke, washer and yoke nut.
4000192a Tighten the yoke nut to 700-900 lb-ft (949-1220 Nm). @
Figure 6.16
Front Input Shaft, Input Shaft Bearing Cage 6. Place the small helical gear over the input shaft and install the
and Oil Pump Assembly spiral snap ring.
1. Place the large O-ring around the groove on the bearing cage. 7. Lubricate the gear and shaft before assembly.
Figure 6.18. 8. Lubricate the sealing rings on the inside diameter of the pump
and the shaft journal adjacent to the pump splines.
Figure 6.18
Figure 6.20.
Figure 6.20
FORWARD
RELIEF VALVE
AND SPRING
LARGE
O-RING SEALING
4000211b RINGS
4005170a
REAR
Figure 6.20
OIL
RELIEF
CAUTION
PORT OIL INLET Exercise care when assembling the input shaft to the pump.
PORTS Line up and slowly direct the input shaft into the pump
opening. Misalignment during assembly can cause the shaft to
hang up on the pump sealing rings resulting in damage to
the rings.
4000201c
Figure 6.19
9. Place the oil pump and input bearing cage assembly over the
input shaft. The drive teeth on the inner pump rotor must
3. Place the bearing cone on the race in the bearing cage. engage the teeth on the input shaft. Do not use force to engage
the splines. If a sealing ring is broken, remove and replace the
4. Insert the relief valve and spring into the relief port of the input pump.
bearing cage. Install the large diameter end of the spring down.
Figure 6.18. Align the oil pump inlet with the oil inlet port of the
input bearing cage. Figure 6.19.
5. 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 Nm). @
4004874b
Figure 6.21
YOKE
SLEEVE
4000212a
DRIVER
Figure 6.24
End of the yoke
must bottom out
in the sleeve driver. 7. Use a feeler gauge to check the seal gap. The seal is correctly
installed if the gap is less than 0.005-inch (0.127 mm) around
the circumference of the seal flange.
If the gap is more than 0.005-inch (0.127 mm): Use a
INPUT POSITION: dead-blow hammer and the appropriate driver to
0.030" 0.030"
(0.76 MM 0.76 MM) completely install the seal.
8. Apply a light coat of transfer case oil to the yoke seal journal.
Before installing the yoke, clean the splines of the old silastic.
4004990b
Apply a 1/8-inch (3.175 mm) bead of RTV 732 sealant
Figure 6.22 360 degrees around the outer two-inches (50.8 mm) of the
yoke splines. Figure 6.25.
Figure 6.23
Figure 6.25
4004991a
Figure 6.23
4005171a
6. Install the input seal. Hold the sleeve and seal only on the outer
Figure 6.25
diameter. Position the seal onto the input seal driver and align it
with the shaft. Do not touch the lips in the inner diameter of the
seal. Use a dead-blow hammer and the appropriate driver to 9. Install the yoke, washer and yoke nut. Loosely tighten the yoke
install the seal onto the output shaft. Figure 6.24. nut at this time. Figure 6.25.
Input Bearing Cage and Oil Pump Assembly 9. Use a pry bar to lift the yoke to obtain a measurement. To obtain
a consistent and averaged reading, perform this operation two or
Installation, Bearing End Play Adjustment
three times. Record the reading for the input shaft.
and Transfer Case Final Assembly
If the end play reading is greater than
1. Rotate the transfer case so that the front is facing UPWARD. 0.001-0.005-inch (0.025-0.127 mm) for MTC-4208
2. Position the shim pack for the input bearing cage and oil pump and -4210 transfer cases, or 0.002 0.001-inch
assembly over the front input opening. Position so that the (0.025 mm) for the MTC-4213 transfer case: Remove
open areas of the shims face the bottom of the transfer case. shims to decrease end play.
If the end play reading is less than specification: Add
3. Lubricate the input bearing cage large O-ring, oil pump, helical
shims to increase end play. Bearing shims come in 0.003-,
drive gear and bearing cone before installation. Use synthetic
0.005- and 0.010-inch (0.08, 0.13 and 0.25 mm)
SAE 50 oil, Meritor specification O-81.
thicknesses.
4. Install the input bearing cage and oil pump assembly. Position
10. If it is necessary to add or remove shims, remove the input
the assembly so that the inlet oil tube fitting is facing the bearing cage and oil pump assembly capscrews and lift the
correct direction. assembly enough to insert or remove shims.
5. Install at least three input bearing cage-to-housing capscrews. This can be done without completely removing the pump
Tighten the capscrews to 85-115 lb-ft (115-156 Nm). @ and shaft assembly from the housing.
6. MTC-4208 and -4210 transfer cases only: Install the large The nut on the rear end of the shaft on MTC-4208 and
3-inch (76 mm) diameter nut onto the rear end of the input -4210 transfer cases must be removed first. Refer to the
shaft. Tighten the nut to 700-900 lb-ft (949-1220 Nm). @ exploded views in this manual.
7. Tighten the input shaft yoke nut to 700-900 lb-ft 11. When the correct shim pack is chosen, reinstall all seven input
(949-1220 Nm). @ bearing cage and oil pump assembly capscrews. Tighten the
capscrews to 85-115 lb-ft (115-156 Nm). @
8. Set up a dial indicator to check input shaft bearing end play.
Center the dial indicator over the shaft using a ball bearing for 12. Recheck the input shaft bearing end play. Adjust the end play
as necessary.
accuracy. Figure 6.26. If a sealing ring is broken, remove and
replace the pump. 13. If necessary, install the breather into the rear cover. Figure 6.27.
Figure 6.27
Figure 6.26
PTO
LOCATION
BREATHER
4000213a
Figure 6.26
REAR OUTPUT
POSITION REAR COVER 4004233a
Figure 6.27
14. Install the oil inlet tube to the lower and upper fittings. Tighten Oil Cooler Ready Model Only
the fitting nuts to 35-40 lb-ft (48-54 Nm). Figure 6.28. @
1. Reinstall the male connector fittings, if removed. Apply Loctite
Figure 6.28
592 threadlocker to the pipe threads. Tighten the fittings to
25 lb-ft (34 Nm). @
2. Connect the oil cooler lines.
If the vehicle is not equipped with an oil cooler:
INLET Reconnect the loop line. Tighten the fittings to 20 lb-ft
OIL TUBE (27 Nm). @
Figure 6.28 4. Apply 60 psi (4.14 bar) or greater of air pressure to the
high-range shaft air port. Figure 6.30.
15. If removed, install the speed sensor into the top of the transfer
Figure 6.30
AIR
CONTROL
PORT
4000218c
Figure 6.30
4000189c
5. Turn the input shaft by hand to verify that the rear output turns
Figure 6.29 at same rate as the input.
16. Install the PTO engagement and disengagement switch 6. Remove the air pressure.
assemblies, if equipped. Otherwise, install a nut and washer 7. Apply 60 psi (4.14 bar) or greater of air pressure to the
into the open port. low-range shaft cylinder air port. Figure 6.30.
17. Reinstall all other pipe threaded plugs using Loctite 8. Turn the input shaft by hand to verify that the rear output turns
592 sealant. at approximately half the rate as the input.
9. Remove the air pressure.
10. For PTO-equipped cases, apply 60 psi (4.14 bar) or greater of Transfer Case Assembly Test
air pressure to the neutral shift location. Figure 6.30.
11. Turn the input shaft by hand to verify that the rear output does CAUTION
not turn at all. Have someone hold the output shafts to prevent The air pressure must not exceed 10 psi (0.69 bar). Damage to
them from turning while spinning the input. components can result.
12. Remove the air pressure. 1. Pressure test the transfer case assembly for air leakage.
13. Remove the transfer case from the stand. 2. Check that the fittings are installed correctly.
14. With the transfer case UPRIGHT, fill the transfer case with the 3. Remove the breather assembly. Figure 6.27.
required lubricant to the fill hole level. Refer to Table G for
volume. 4. With the correct fitting installed into the breather port, apply a
pressure of 8-10 psi (0.55-0.69 bar).
Adjust the Oil Level 5. Shut the air supply off.
1. Clean the area around the fill plug. Remove the fill plug from If the pressure decreases by more than 2 psi (0.14 bar)
the transfer case. in 10 minutes: Check for external leaks at the fittings.
2. Add the specified oil until the oil level is even with the bottom of 6. Correct the leakage problem and retest.
the fill plug hole.
7. Reinstall the breather assembly.
3. Install and tighten the fill plug to 35-50 lb-ft (47-68 Nm). @
4. Test drive the vehicle for at least one mile (1.6 km). Allow the
oil to settle for five minutes and recheck the fluid level. Top off
the oil level by adding oil to the fill opening. Reinstall and
tighten the fill plug to 35-50 lb-ft (47-68 Nm). @
WARNING
Failure to correct an oil leak or operating the transfer case low
on oil could result in damage to the transfer case. In addition,
overfilling the oil level will cause excessive heat and damage
to the transfer case.
CAUTION
Use only SAE Grade 50W full synthetic oil in the transfer case.
Do not use multi-viscosity engine oils or Extreme Pressure (EP)
GL-5 gear oils. Damage to components can result. Refer to
publication TP-90114, Transmission Lubricant Specifications,
for a list of approved distributors.
Read and observe all Caution and Warning safety alerts below and Part Name Qty. Part Number Description
those that precede instructions or procedures you will perform. PTO 1 MDP-10-AF-100 10,000 lb-ft
Assembly (13 500 Nm)
WARNING torque rating
To prevent serious eye injury, always wear safe eye protection Washer 8 1229-E-1513 0.81" O.D. x 0.47" I.D.
when you perform vehicle maintenance or service. x 0.09" thickness
When you apply some silicone gasket materials, a small Capscrew 6 S-2710-2 7/16" - 14 thread x
amount of acid vapor is present. To prevent serious personal 1.25" long
injury, ensure that the work area is well-ventilated. Read the Capscrew 2 S-2746-2 7/16" - 14 thread x
manufacturers instructions before using a silicone gasket 5.75" long
material, then carefully follow the instructions. If a silicone Washer 1 1229-T-1736 2.36" x 1.56 I.D. x
gasket material gets into your eyes, follow the manufacturers 0.12" thickness
emergency procedures. Have your eyes checked by a
Locknut 1 40-X-1237 M39 x 1.5 thread
physician as soon as possible.
Dowel Pin 2 1246-T-1190 3/8" diameter x 1" long
Take care when you use Loctite adhesive to avoid serious
personal injury. Read the manufacturers instructions before
using this product. Follow the instructions carefully to prevent
irritation to the eyes and skin. If Loctite adhesive material
gets into your eyes, follow the manufacturers emergency
procedures. Have your eyes checked by a physician as soon
as possible.
Installation
This section provides instructions on installing a power take-off
(PTO) assembly onto Meritor MTC-4208 and -4210 transfer cases
using Kit 2540. Refer to Table C and Figure 7.1. Refer to the Service
Notes page on the front inside cover of this manual to obtain this Kit.
Figure 7.1
PTO MDP-10-AF-100
10 12
9
15 * 8
7
4
17
19
13
18
14
6
5
2
11 *
3 1 21
20
16
4000221a
Figure 7.1
Remove the Transfer Case Rear Access 4. Remove the eight mounting bolts and washers that secure the
Cover transfer case rear access cover. Remove the cover. Figure 7.2.
1. Park the vehicle on a level surface. Block the wheels to prevent 5. Clean the PTO mounting surface to remove all sealant.
the vehicle from moving.
2. Remove the air from the vehicles system.
3. Place a suitable container under the transfer case to catch the
hydraulic fluid that will drain when you remove the rear access
cover.
Figure 7.2
10 11 12
13
5 3 2
4
6
8 7
1 4000219a
Figure 7.2
Figure 7.3 2. Apply a 1.8-inch (46 mm) bead of RTV silicone gasket material
around the end of the yoke spline under the washer surface.
3. Install the washer and locknut supplied in the kit. Tighten the
locknut to 700-900 lb-ft (949-1220 Nm). @
1. Remove the screw and washer from the end of the PTO cap.
Figure 7.4.
Figure 7.4
OPTIONAL
CONNECTOR
SWITCH
ASSEMBLY
SWITCH PORT
Figure 7.3 SCREW AND AIR CONTROL
WASHER PORT
2. Apply Loctite 518 gasket sealant to the indicator switch Figure 7.6
threads. AIR
CONTROL PTO
3. Install the indicator switch. Tighten the switch to 25-30 lb-ft PORT ASSEMBLY
(34-41 Nm). Figure 7.5. @
PTO SWITCH
Figure 7.5
(OPTIONAL)
OPTIONAL
INDICATOR CONNECTOR
SWITCH SWITCH
ASSEMBLY
SPECIAL PLUG
AND WASHER
4000217a
AIR
CONTROL Figure 7.6
PORT
The air pressure must not exceed 90 psi (6.2 bar). Damage to
components can result.
PTO with an Optional Indicator Switch 2. Check that the air pressure line fittings are installed correctly.
1. Install the indicator switch. Tighten the switch to 25-30 lb-ft 3. With the correct fitting installed into the breather port, apply a
(34-40.8 Nm). @ pressure of 8-10 psi (0.55-0.69 bar).
2. Verify that the indicator switch closes when the PTO completes 4. Turn the air supply OFF. Check the pressure.
a shift to engage the drive. Figure 7.5.
If the pressure decreases by more than 2 psi (0.14 bar)
If the indicator switch does not close to fully engage in 10 minutes: Check for external leaks at the fittings.
the drive: Measure the PTO push rod travel to verify that Correct any leaks. Recheck the pressure.
the travel is 0.75-inch (19 mm) and that the clutch is fully
engaged. 5. Install the breather.
If the push rod travel is not at 0.75-inch (19 mm) and PTO Assembly
the PTO clutch is not fully engaged: Disengage the
clutch by releasing the air pressure. Rotate the clutch 1. Rotate the transfer case in the repair stand so that the output
output shaft by hand and retest. shaft to the PTO is facing UPWARD.
If the clutch still is not fully engaged: Remove the PTO
assembly. Check the transfer case output shaft splines and CAUTION
the PTO clutch collar splines. Replace worn or damaged The cups must fit securely in the housing bores. Damage to
parts. Repeat the assembly procedures. the components can result.
Test the Transfer Case with the PTO 2. Assemble the PTO components by performing the following
steps.
Assembly Installed
A. Install the bearing cups into the PTO bearing cage
CAUTION housing. This is an interference fit. Freeze the bearing to
The air pressure must not exceed 10 psi (0.69 bar). Damage to 65 F ( 54 C) and position the two cups into the
components can result. housing bores. Figure 7.8.
1. Connect a regulated air pressure line to the air transfer case If the cups are loose after the cup temperature
breather. Figure 7.7. warms: Replace the housing.
Figure 7.8
Figure 7.7
PTO
LOCATION
BREATHER
BEARING
CUP 4000222a
Figure 7.8
REAR OUTPUT
POSITION REAR COVER 4004233a
Figure 7.7
B. Preheat the first bearing cone to 200 F (93 C). Support I. Apply 20-30 lbs (9-14 kg) of pressure to insert the piston
the shaft and slide the heated cone in place onto the into the housing. Figure 7.11.
output shaft. Figure 7.9.
Figure 7.11
Figure 7.9
PUSH ROD PISTON
BEARING
CONE
COVER
SHIFT PLATE
FORK
SHAFT
D. With the bearing spacer in position, the second bearing L. Install the 1/4-20 screws using Loctite 242 sealant.
cone can be heated to 200 F (93 C) and installed onto Tighten the screws to 10-14 lb-ft (14-19 Nm). @
the shaft. Figure 7.10. M. Insert the spring into the housing over the push rod.
Figure 7.12.
Figure 7.10
Figure 7.12
SPRING
BEARING
CONE CAP
SPACER
4000224a
Figure 7.10
SEAL
4000226a
E. Support the shaft and apply a press of 50-60 lbs Figure 7.12
(23-27 kg) to the bearing cone to set the bearing in place
while the bearing cools. N. Apply a thin film of Loctite 518 gasket material to the
F. Apply a light film of SAE 50W synthetic lubricant. cap surface. Install the cap with the 1/4-20 screws using
Loctite 242 sealant. Tighten the screws to 10-14 lb-ft
G. Assemble the shift fork to the clutch collar. Install this unit
(14-19 Nm). Figure 7.12. @
into the bearing cage housing.
O. Install the PTO shaft seal into the housing.
H. Install the push rod into the housing and through the shift
fork assembly. P. Press the seal into position until the seal is seated on the
housing.
3. Install the PTO assembly onto the transfer case. Figure 7.13
C. Check for external leaks at the cover plate joint and fitting
if the pressure decreases more than 5 psi (0.3 bar) in
10 minutes.
If the external joints are sealed and the leakage is
still more than 5 psi (0.3 bar): Remove the piston
and inspect the O-ring and housing bore for damage.
Repair parts as necessary.
9. Install the indicator switch. Tighten the switch to 25-30 lb-ft
(34-40 Nm). Figure 7.13. @
If a switch is not used: Install the special plug and washer
used to cap the access hole. Tighten the plug to 25-30 lb-ft
(34-40 Nm). Figure 7.13. @
Hazard Alert Messages 2. Clean the area around the fill plug. Remove the fill plug from
8 Installation
the transfer case. Figure 8.1. The oil level must be even with
Read and observe all Warning and Caution hazard alert messages in the bottom of the fill plug hole.
this publication. They provide information that can help prevent
If oil flows from the hole when you loosen the plug: The
serious personal injury, damage to components, or both.
oil level is high. Drain the oil to the bottom of the fill hole.
WARNING If the oil level is below the bottom of fill/level plug hole:
Add the specified oil until oil is even with the bottom of the
To prevent serious eye injury, always wear safe eye protection
fill hole.
when you perform vehicle maintenance or service.
3. Install and tighten the fill plug to 35-50 lb-ft (47-68 Nm). @
Install the Transfer Case 4. Test drive the vehicle for at least one mile (1.6 km). Allow the
oil to settle for five minutes and recheck the fluid level. Top off
WARNING the oil level by adding oil to the fill opening. Reinstall and
Support the transfer case with a lifting device before moving tighten the fill plug to 35-50 lb-ft (47-68 Nm). @
the transfer case. A transfer case that is not supported Figure 8.1
Troubleshooting
9 Diagnostics
Clean transfer
case and operate
vehicle.
Does oil
No blow-out from
the breather?
Yes
4001525b
Figure 9.2
Continued from
previous page.
No
4001526b
Yes
Replace broken
brackets and/or Loose
tighten all Yes fasteners or No
fasteners to broken
specified torque. bracket?
Return the
vehicle to service. 4001527b
Replace faulty
Light or Yes indicator light or
sensor sensor, then try to
faulty? shift PTO.
No
Yes
No
Verify that the PTO engages and
Remove the PTO from the transfer case. disengages correctly.
Disassemble the PTO and inspect the
bearings, shift collar, shift fork declutch
bore and return spring for damage. Repair Check the PTO for leaks.
all damaged components.
Replace faulty
Light or Yes indicator light or
sensor sensor, then try to
faulty? shift declutch.
No
Yes
No
Check the available air pressure. The transfer case requires
at least 60 psi (4.14 bar) at all times to operate correctly.
Correct system
air pressure.
Air Refer to the Return the
pressure 65 psi No
vehicle vehicle to
(4.48 bar) or manufacturers service.
more? instructions.
Yes
Check the piston
cylinder. If dirty,
Air disassemble shifter Return the
Yes Air blowing No Yes
system components for vehicle to
out the housing
contaminated? cleaning. Clean the service.
breather.
air supply system.
Refer to vehicle
No
manufacturers
instructions. Check
Remove the transfer that the transfer
case from the vehicle. case shifts correctly.
Air blowing No
Disassemble and
out the neutral
replace housing
breather or
O-ring and piston
port.
O-rings. Reassemble Remove the shift cylinder and pistons. Inspect
and check that Yes O-rings, pistons, snap rings and shift bore.
transfer case shifts Repair any damaged components. Reassemble
correctly. and check that transfer case shifts correctly.
Reinstall transfer
Problem Yes case in vehicle Problem Yes Return vehicle
fixed? and return fixed? to service.
vehicle to service.
No No
Disassemble transfer case and inspect shift shaft, shift fork,
Contact ArvinMeritors
shift collar and shift bore. Repair any damaged components.
Customer Service
Reassemble and check that the transfer case shifts correctly.
Center at 800-535-5560.
4001530c
Read and observe all Warning and Caution hazard alert messages in
CAUTION
this publication. They provide information that can help prevent
Meritor does not approve petroleum-based and multiviscosity
serious personal injury, damage to components, or both.
oil. Do not install API GL-5 oils, which contain
extreme-pressure (EP) additives. These additives can form
WARNING
sludge at normal operating temperatures. Damage to
To prevent serious eye injury, always wear safe eye protection
components can result. Use only SAE Grade 50W synthetic oil
when you perform vehicle maintenance or service.
in the transfer case.
How to Obtain Additional Lubrication Use only SAE Grade 50W oil, Meritor specification O-81, in the
and Maintenance Information transfer case.
For complete lubrication information for Meritors transfer cases, Do not install API GL-5 oils in a transfer case. This specification
refer to Maintenance Manual 1, Preventive Maintenance and contains extreme pressure (EP) additives that can form sludge at
Lubrication. To obtain a copy of this publication or access it on normal operating temperatures and damage transfer case
ArvinMeritors website, refer to the Service Notes page on the inside components.
front cover of this manual.
Petroleum-Base and Multi-Viscosity Oils
Lubricant Temperatures Meritor does not approve the use of petroleum-base and
multi-viscosity motor oils. Refer to Maintenance Manual 1,
Meritor MTC-4208, MTC-4209 and Preventive Maintenance and Lubrication; or TP-90114,
MTC-4210 Series Transfer Cases Transmission Lubricant Specifications, for a list of approved oils.
Meritor does approve the use of synthetic-base oils.
CAUTION
Meritor MTC-4208, MTC-4209 and MTC-4210 Series transfer
cases may operate with an oil temperature above 300 F
Operating Information
(148 C). However, if the oil temperature reaches 350 F
(177 C), stop the vehicle immediately. Check for the cause of
Magnets and Magnetic Drain Plugs
overheating to prevent damage to components. Most Meritor transfer cases are equipped with magnetic drain plugs
with a minimum pick-up capacity of 20 ounces (0.57 kg) of low
Meritor MTC-4208, MTC-4209 and MTC-4210 Series transfer carbon steel. Replace the magnetic drain plug each time you
cases may operate with an oil temperature above 300 F (148 C). change the oil. Use the correct part. If you use a pipe plug instead of
However, if the oil temperature reaches 350 F (177 C), stop the a drain plug, the pipe plug will leak.
vehicle immediately and check for the cause of overheating. Oil
You can reuse a drain plug you removed if it has a minimum pick-up
temperatures at this range should only occur in linehaul or utility
capacity of 20 ounces (0.57 kg) of low carbon steel after you clean
applications that operate under high speed for long periods of time.
it.
Breather
CAUTION
Cover the breather when steam cleaning the housing. If the
breather is not covered, water can enter the housing and
contaminate the oil.
PTO FRONT
LOCATION BREATHER OUTPUT INPUT
POSITION POSITION
Figure 10.2
REAR OUTPUT
CAUTION
POSITION BREATHER Only install the Meritor multi-lip unidirectional seal at the input
position from the transmission in an MTC-4208, MTC-4210 or
MTC-4213 Series transfer case. If you install the multi-lip seal
in either the rear output position or forward output position on
these transfer cases, loss of lubricant and damage to
components can occur.
The multiple-lip seal must be serviced with the seal and sleeve. The
MTC-4213 REAR COVER
4004233e service part number provides both when required. Check your
application carefully before installing the multiple-lip seal.
Figure 10.2
Seals keep lubricant in and dirt out of a component. When they are
worn or damaged, seals leak and produce low lubricant levels which
may damage components.
Always replace unitized seals after yokes have been removed. MLS
seals may be reused if they are not damaged or leaking.
Meritor has released the multiple-lip seal (MLS) for use in the INPUT
POSITION ONLY on the MTC-4208, -4210 and -4213 transfer
cases. The multiple-lip seal is compatible with the current input
shaft seal and can be used in service. Refer to Figure 10.3 for the
INPUT position and front OUTPUT position. Refer to Figure 10.1 for
the MTC-4208 and -4210 rear OUTPUT position. Refer to
Figure 10.2 for the MTC-4213 rear OUTPUT position.
Breather
Fill and drain plugs
Pump inlet tube and fittings
Gaskets and shims
During the inspection visually check to ensure the transfer case
oil level is to the bottom of the oil fill hole.
Torque Specifications
11 Specifications
Figure 11.1
13
3
FRONT
6 15 7
5
8 12
10
11
4000229c
Item Description Torque lb-ft (Nm) Item Description Torque lb-ft (Nm)
1 Bearing Cage Cover Capscrews 85-115 (115-156) 9 Shaft Locknut 700-900 (949-1220)
2 Loop Tube Fittings 20 (27) 10 Bearing Cage Capscrews 85-115 (115-156)
3 Oil Cooler Male Connectors* 25 (34) 11 Shaft Locknut 700-900 (949-1220)
4 Yoke Locknuts 700-900 (949-1220) 12 Oil Pump Capscrews 22-29 (29-39)
5 Magnetic Drain Plug 35-50 (48-68) 13 Shift Cylinders 85-95 (115-129)
6 3/8-Inch (9.5 mm) Plug 20-25 (27-34) 14 Male Connector 35-50 (48-68)
7 Fill Plug 35-50 (48-68) 15 Fitting Screen 35-50 (48-68)
8 Cover-to-Case Capscrews 60-75 (81-102) * Apply Loctite 582 threadlocker to pipe threads
Guidelines
12 Vehicle Towing Instructions
CAUTION
Follow towing procedures recommended by Meritor to prevent
internal damage to the transfer case.
Meritor recommends that you use one of the two methods below
when towing a vehicle equipped with an MTC-4208, -4210 or
-4213 transfer case to prevent damage to the transfer case.
Method 1
Remove both axle shafts from the axles that will remain on the road
when the vehicle is transported.
Method 2
Remove the drive shafts from axles that contact the ground.
Tool Drawing
13 Special Tools
Figure 13.1
0.12
2.50
A
4.75
A 3.00
.030 A
4.50 A
1.00 SQUARE
SECTION AA
SCALE 1:2
0.25
1.00
2-HOLES A
MIN. HEX 4.25
2.32 0.56 DEPTH
CORNER
RELIEF
0.50 ACCEPTABLE
2.25 3.00
1.73
0.50 A
1.00
1.00
1.20 4.50 1.50
SQUARE
6.20 3.00
HEX
SECTION AA
4004222a
SCALE 1:2