Meritor T-2111 Series Maintenance Manual
  1. Manuals
  2. Brands
  3. Meritor Manuals
  4. Industrial Equipment
  5. T-2111 Series
  6. Maintenance manual

Meritor T-2111 Series Maintenance Manual

Transfer cases
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Meritor MTC3111 (T-2111) Series Transfer Case Service
Pro Gear Meritor MTC3111 (T-2111) Transfer Case Parts Manual to assist in identifying your
Meritor / Fabco unit.
If you need any assistance identifying the correct transfer case unit for your truck and
equipment, 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 for your next project.
For parts or service contact the Meritor / Fabco specialists at Pro Gear & Transmission, Inc.
1 (877) 776-4600
(407) 872-1901
parts@eprogear.com
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 (877) 776-4600 / (407) 872-1901 • parts@eprogear.com
Manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the T-2111 Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Meritor T-2111 Series

Summary of Contents for Meritor T-2111 Series

  • Page 1 Pro Gear Transmission has same day shipping and 1000’s of products in stock and ready to ship internationally for your next project. For parts or service contact the Meritor / Fabco specialists at Pro Gear & Transmission, Inc. 1 (877) 776-4600 (407) 872-1901 parts@eprogear.com...
  • Page 2 T-2111 Series Transfer Cases 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 Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 (877) 776-4600 / (407) 872-1901 • parts@eprogear.com...
  • Page 3 SERVICE NOTES This Maintenance Manual describes the correct service and repair procedures for the Rockwell T-2111 Series Transfer Case. The information contained in this manual was current at the time of printing and is subject to change without notice or liability.
  • Page 4 P.T.O. DECLUTCH DCM BRAKE 175B 175A 209A OIL PUMP MAIN CA 142A PROPORTIONAL DIFFERENTIAL DECLUTCH 156A 157A 119 120 121 122 124 123 108A 108B 108D 115A 108C 114A NOTE: Parts show wn are not used on all mod els. Pro Gear and Transmission •...
  • Page 5 20 Washer-brake 97 Shim-idler gear 170 Oil Seal Assy.-declutch cage 21 Nut-lock 98 Plug-oil suction 22 Deflector-brake adapter T-2111 SERIES 11,000 LB-FT DECLUTCH/P.T.O. 23 Dust Shield 99 Plug-transfer case 171 Shaft-declutch 24 Oil Seal-brake bearing cage 100 Plug-oil fill 172 Collar-clutch...

  • Page 6: Table Of Contents

    Table of Contents SUBJECT PAGE Asbestos and Non-Asbestos Fiber Warnings ..................2 1. Introduction Description................................3 Operation ................................5 Identification................................6 2. Removal and Installation Remove Transfer Case from Vehicle .........................7 Install Transfer Case in Vehicle .........................8 Drain and Replace Oil............................8 Check and Adjust Oil Level ..........................8 3.

  • Page 7: Subject Page

    Table of Contents (continued) SUBJECT PAGE Install Output Shaft and Bearing Cage Assembly ....................27 Assemble Parking Brake ..........................27 Application of Silicone Gasket Material ......................29 6. Lubrication Recommended Oil ............................30 Oil Substitutes..............................30 Acceptable Motor Oil Alternatives........................30 Transfer Case Oil Levels ..........................31 7.

  • Page 8: Asbestos And Non-Asbestos Fiber Warnings

    NON-ASBESTOS ASBESTOS FIBER WARNING FIBER WARNING The following procedures for servicing brakes are recommended The following procedures for servicing brakes are recommended to reduce exposure to asbestos fiber dust, a cancer and lung to reduce exposure to non-asbestos fiber dust, a potential cancer disease hazard.

  • Page 9: Introduction

    Section 1 Introduction Figure 1 TYPICAL 4x4 HOOKUP Air actuated options include: Description • Axle declutch option permits shifting from The Rockwell T-2111-D, T-2111-PD, T-2111-T, 4-wheel drive to 2-wheel drive. Figure 2. T-2111-HP and T-2111-SD/SPD/ST transfer cases are a three-shaft design with single speed front and rear output and 1:1 ratio for use with 4x4 and 6x6 Figure 2 vehicles.
  • Page 10 Section 1 Introduction • • PD option transfer cases permit full-time All-wheel Proportional Differential with a 30/70 torque split drive. Figure 3. (Front axle, 30%; rear axle, 70%) can be locked up to give full power to each axle. Figure 5. Figure 3 Figure 5 INPUT...

  • Page 11: Operation

    Section 1 Introduction Operation CAUTION NOTE: • The declutch and PD lockup should only be • The Axle Declutch and Proportional Differential locked under poor operating conditions. (PD) Lockup provide maximum vehicle traction Turning radius and steering responsiveness on poor operating surfaces. Both provide will be different in the locked condition.

  • Page 12: Identification

    Section 1 Introduction Identification T-2111 TRANSFER CASE T - 2 1 1 1 - T 1 0 1 - 1 0 0 Rockwell transfer case. 1.00:1 ratio. (standard) Specification sequence number Number of speeds in transfer case. associated with Bill of Material Basic transfer case rating in Thru shaft configuration* thousands of ft..

  • Page 13: Removal And Installation

    Section 2 Removal and Installation Remove Transfer Case from 9. Use a hydraulic roller jack to support the transfer case. Remove the mounting bolts that hold the case Vehicle to the vehicle. 10. Carefully remove the transfer case with the WARNING hydraulic jack.

  • Page 14: Install Transfer Case In Vehicle

    Section 2 Removal and Installation Install Transfer Case in Vehicle 3. Install and tighten the drain plug to 35-50 lb-ft (47-68 N•m). 1. With a lifting device, remove the transfer case from the repair stand to a hydraulic roller jack. If used, Figure 7 T-2111 SHOWN (TYPICAL) remove the temporary eyebolts and angle iron...

  • Page 15: Disassembly

    Section 3 Disassembly 5. Use a brake shoe return spring removal tool to Disassemble Parking Brake 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 reassembly. WARNING To prevent serious eye injury, always wear safe eye 6.

  • Page 16: Disassemble Proportional Differential

    Section 3 Disassembly Figure 9 PLANET GEAR GEAR PLANET SHAFT RING GEAR SCREW PLANETARY SPIDER SPACER DIFF. BRG. CAGE FRONT REAR OUTPUT OUTPUT SPACERS BRAKE ADAPTER Disassemble Proportional Disassemble Planetary Differential Spider Assembly NOTE: 1. Remove the snap ring from the ends of the planet Refer to Figure 9 to disassemble the proportional shafts.

  • Page 17: Disassemble Yokes From Input And Output Shafts

    Section 3 Disassembly Disassemble Yokes from 2. Remove the capscrews and washers that attach the bearing cages to the transfer case housing. Input and Output Shafts CAUTION 1. Rotate the transfer case in the repair stand so the yokes face upward. Be careful not to damage the shims when removing the bearing cage.

  • Page 18: Disassemble Declutch Assembly

    Section 3 Disassembly Disassemble Declutch CAUTION Assembly Be careful not to damage the shims when removing the bearing cage. Damaged shims can 5450 ft. lb. (7400 N•m) Version: Figure 12. cause fluid leakage. 11. Lift the bearing cage and shaft assembly from the DECLUTCH Figure 12 housing.

  • Page 19: Disassemble Proportional Differential Lockout And Front Output Shaft Assembly

    Section 3 Disassembly Disassemble Proportional 15. Remove the sliding declutch collar. Differential Lockout and 16. Remove the ball bearing from the declutch output shaft. Front Output Shaft Assembly 1. Rotate the transfer case in the repair stand so that Disassemble Housing Halves the declutch assembly is facing upward.

  • Page 20: Disassemble Bearing Cages And Differential Cover From Housing

    Section 3 Disassembly 4. Lift and remove the three gear and shaft assemblies Disassemble Idler Gear, Input from the bottom of the case. Figure 15. and Output Shaft Assemblies Figure 15 1. Use a bearing puller to remove the bearing cones from the idler gear assembly.

  • Page 21: Cleaning And Inspection

    Section 4 Cleaning and Inspection Clean Ground and Dry Cleaned Parts Polished Parts 1. Dry the parts immediately after cleaning and washing. 2. Dry the parts with clean soft paper or cloth rags. WARNING To prevent serious eye injury, always wear safe eye protection when doing maintenance or service.

  • Page 22: Inspect Parts

    Section 4 Cleaning and Inspection Inspect Parts Figure 17 It is very important to inspect all parts carefully and completely before the transfer case is assembled. Check all parts for wear and stress. Replace all damaged parts. Replacement of the damaged parts before assembly can prevent complete failure of the assembly later.
  • Page 23 Section 4 Cleaning and Inspection G. The cup and cone inner race surfaces that touch 5. Inspect the brake drum: the roller are damaged. Figure 20. A. Remove all dirt from the drum. Figure 20 B. Inspect the inside of the drum for cracks or SPALLING &...

  • Page 24: Assembly

    Section 5 Assembly Assemble Input Shaft, 3. Press the bearing cones on to the other ends of the shafts until they are flat against the gears. Figure 21. Idler Gear and Output Shaft Assemblies Figure 21 WARNING To prevent serious eye injury, always wear safe eye protection when doing maintenance or service.

  • Page 25: Assemble Bearing Cages And Differential Cover In Rear Case Half

    Section 5 Assembly Assemble Bearing Cages 3. Align the capscrew holes of the input bearing cage and the housing. Use the match marks made at and Differential Cover in disassembly. Figure 24. Rear Case Half Figure 24 1. Rotate the rear case half in the repair stand so that the outside of the case faces upward.

  • Page 26: Assemble Transfer Case Housing

    Section 5 Assembly 4. Set the three shaft assemblies in their correct 2. Use the lifting loops or eye bolts to lift the other positions in the housing. Make sure that the gear housing half and put it in the correct position. teeth are correctly engaged.
  • Page 27 Section 5 Assembly 6. Measure the gap between the cage and the 9. Assemble the bearing cap and correct shim pack to mounting surface on the housing at the two the housing with eight capscrews and washers. capscrews with a feeler gauge. Figure 28. Tighten the capscrews to 60-75 lb-ft (81-102 N•m).

  • Page 28: Check Bearing Endplay

    Section 5 Assembly Check Bearing End Play NOTE: The movement indicated by the dial indicator is the preliminary end play that exists with the initial shim 1. Install the yoke nut on the input shaft finger tight. stack. 2. Set a small steel ball in the hole on the end of the c.

  • Page 29: Assemble Front Output Shaft Differential Lockout Assembly

    Section 5 Assembly Figure 31 PLANET GEAR GEAR PLANET SHAFT RING GEAR SCREW PLANETARY SPIDER SPACER DIFF. BRG. CAGE FRONT REAR OUTPUT OUTPUT SPACERS BRAKE ADAPTER Assemble Front Output 8. Fit the shift fork through the cage opening and on to the shift collar.

  • Page 30: Install Yokes

    Section 5 Assembly 13. Install the set screw and tighten to 15-25 lb-ft (20-34 Figure 32 N•m). WARNING Small amounts of acid vapor are present when applying silicone gasket material. To prevent possible serious personal injury, make sure there is good ventilation in the work area. If the silicone gasket material gets in your eyes, flush your eyes with water for 15 minutes.

  • Page 31: Assemble Proportional Differential

    Section 5 Assembly Figure 33 PLANET GEAR GEAR PLANET SHAFT RING GEAR SCREW PLANETARY SPIDER SPACER DIFF. BRG. CAGE REAR FRONT OUTPUT OUTPUT SPACERS BRAKE ADAPTER Assemble Proportional 7. Install the ring gear and snap ring on the output shaft. Differential 8.
  • Page 32 Section 5 Assembly 2. Install the yoke and nut on the shaft finger tight. 7. Remove the yoke nut and yoke, then remove the bearing cage/output shaft assembly from the transfer 3. Set a small steel ball in the hole on the end of the case.

  • Page 33: Install Output Shaft And Bearing Cage Assembly

    Section 5 Assembly Install Output Shaft and Assemble Parking Brake Bearing Cage Assembly 1. Install a new seal into the brake adapter with the correct size driver. Make sure that the seal is flat in 1. After correct bearing end play has been achieved, the bore and flush with the adapter face.
  • Page 34 Section 5 Assembly 4. Assemble the cam (1) through the backing plate 10. Install the two remaining new shoe return springs (2), lever, lock washer and nut. Tighten the nut to with spring pliers. give an end play of 0.001” to 0.010” (.025 mm to .254 mm) as measured with a feeler gauge 11.

  • Page 35: Application Of Silicone Gasket Material

    Section 5 Assembly Application of Silicone 4. Apply a 0.125 inch (3.18 mm) diameter continuous bead of silicone gasket material around one surface. Gasket Material Also apply the gasket material around the edge of all the fastener holes on that surface. Figure 35. WARNING Figure 35 0.125"...

  • Page 36: Lubrication

    Section 6 Lubrication Recommended Oil Oil Substitutes API GL-1 85W CAUTION API GL-1 90W • API GL-1 140W Rockwell does not approve the use of multi- viscosity motor oils. Multi-viscosity API GL-1 oils within the recommended viscosity range are CAUTION acceptable but not suggested if another option is Do not use API GL-5 oils as transfer case available.

  • Page 37: Transfer Case Oil Levels

    Section 6 Lubrication Oil Fill Options Transfer Case Oil Levels Figure 36 WARNING • Use only the type of lubricant specified by the equipment manufacturer. Do not use or mix different types of lubricant. The wrong lubricant can cause damage, incorrect operation and serious personal injury.

  • Page 38: Diagnostics

    Section 7 Diagnostics Diagnostics:T-2111 Series Transfer Cases Possible Cause Problem 1. Excess lube quantity Overheating 2. Incorrect lube viscosity 3. Excessive speed (RPM) 4. Excessive axle ratio (Tire size mismatch) 1. Excessive speed (RPM) Oil blowing out of breather 2. Excess lube quantity 3.

  • Page 39: Specifications

    Section 8 Specifications T-2111-D/SD, T-2111-PD/SPD, T-2111-T/ST and T-2111-HP/SHP Specifications* *GVW RATING: (TYPICAL) TYPE: 80,000 lbs. (36,288 kg) Three Shaft Design (Based on 15 x 22.5 Tire and 3.91 Axle Ratio) Single Speed Front and Rear Outputs WEIGHTS: (less oil) INPUT TO OUTPUT DROP: MODEL COMPONENT LBS.

  • Page 40: Transfer Case Oil Change Intervals

    Section 8 Specifications Transfer Case Oil Change Intervals Off-Highway Intervals On-Highway Check Initial Scheduled Check Initial Scheduled Level Change Change Level Change Change 40 operating 40-100 operating 200-300 operating 2,000 mi 2,500 mi 12,000 to 25,000 mi hours hours hours (3219 km) (4023 km) (19312 to 40233 km)

  • Page 41: Driveline Application Guideline

    Section 8 Specifications Driveline Application Guideline NOTE: All of the options shown below may not be available for each transfer case configuration. The values given are for Rockwell manufactured parts. If parts from other manufacturers are used, torque values may be different. WING STYLE MAX TORQUE YOKES...

  • Page 42: Torque Chart

    Section 8 Specifications Torque Chart Figure 37 ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE Housing Capscrews 60-75 lb-ft (87-102 N•m) Brg. Cage Capscrews 60-75 lb-ft (87-102 N•m) Brake Backing Plate Drain and Fill Plugs 35 lb-ft (47 N•m) Minimum Capscrews 180-230 lb-ft (244-312 N•m) Set Screws 15-20 lb-in (1.6-2.2 N•m) Diff.

  • Page 43: Tire Mismatch

    Section 8 Specifications Tire Mismatch Acceptable limits for calculations: With thru shaft between front and rear output: NOTE: • Positive mismatch calculations indicate the High speed mismatch: ± 1.5% front axle is PULLING. Low speed mismatch: ± 1.0% • Negative mismatch calculations indicate the rear axle is PUSHING.

  • Page 44: T-2111 Transfer Case Variations

    Section 8 Specifications T-2111 TRANSFER CASE VARIATIONS 1) T-2111 VERTICAL CASE (T-2111-T [THRU DRIVE ] MODEL SHOWN) ALSO USED ON MODELS: T-2111-D T-2111-PD 16.12 T-2111-HP 6.75 2) T-2111 SHORT DROP CASE WITH OFFSET ORIENTATION: (T-2111-ST [THRU DRIVE ] MODEL SHOWN) ALSO USED ON MODELS: 9.32 T-2111-SD...
  • Page 45 NOTE: For more information on parts and kits, see Meritor publication PB-90199, T-215 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...
  • Page 46 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 discontinue the production of parts described at any time.

This manual is also suitable for:

T-2111-dT-2111-pdT-2111-tT-2111-hpT-2111-sdT-2111-spd ... Show all

Table of Contents