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Meritor MM-0861 Maintenance Manual

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MAINTENANCE MANUAL MM-0861
MTC-4208X/XL/XP/XLEV/XLEC, MTC-4210X/XL/XP/
XLEV/XLEC AND MTC-4213X SERIES TRANSFER CASES

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Summary of Contents for Meritor MM-0861

  • Page 1 MAINTENANCE MANUAL MM-0861 MTC-4208X/XL/XP/XLEV/XLEC, MTC-4210X/XL/XP/ XLEV/XLEC AND MTC-4213X SERIES TRANSFER CASES...

  • Page 2: About This Manual

    9355. components. In addition, GS models cannot be used in place of For assistance with parts, you may also contact the Meritor Parts the X models in applications with “engage-on-the-fly” systems or Center in Florence, KY at CustCareCntr.Florence@Meritor.com or mid-ship pumps.

  • Page 3: Table Of Contents

    MTC-4213X Transfer Case Front Cover ....30 MTC-4208XP and MTC-4210XP Declutch/PTO .. 32 Section 3: Introduction ........34 Model Nomenclature ........34 Description ............35 Operation ............37 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page i...

  • Page 4: Transfer Case Interchangeability

    PTO Assembly ..........85 Modified Bearing Cup Puller ......115 Section 9: Installation ........88 Install the Transfer Case ........88 Oil Cooler Line Connections ......88 MM-0861 / Revised 06-22 Page ii Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 5: Section 1: Safety Information

    • Use only wheels and valve stems approved by the vehicle manufacturer for use with Meritor air disc brakes. Use of • Follow all safety instructions and service guidelines unapproved wheels and valve stems can result in valve stem established at the service facility where work is being damage.

  • Page 6: Section 2: Exploded Views

    Exploded Views Exploded Views MTC-4208X/XP Transfer Case Rear Cover 4007388a MM-0861 / Revised 06-22 Page 4 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 7 * Vehicles not equipped with a transfer case neutral air control may be equipped with a neutral breather which allows the shift cavity to exhaust. On vehicles equipped with a neutral air control, the solenoid allows this cavity to exhaust. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022...

  • Page 8: Mtc-4208X/Xp Transfer Case Front Cover

    Exploded Views MTC-4208X/XP Transfer Case Front Cover 15 16 FRONT 4007389a MM-0861 / Revised 06-22 Page 6 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 9 Male Fitting Oil Fill Plug Oil Pump Assembly Shift Piston Bearing Cone Shift Piston O-ring Shim Shipping Protector Input Bearing Cage Shift Cylinder Bearing Cage Capscrew and Washer MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 7...

  • Page 10: Mtc-4208Xl Transfer Case Rear Cover

    Exploded Views MTC-4208XL Transfer Case Rear Cover 4007101a MM-0861 / Revised 06-22 Page 8 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 11 Lock Nut Blow-by Breather Oil Pump Inlet Tube Neutral Breather Tube Assembly, without Oil Cooler Shipping Protector Oil Pump Inlet Fitting Neutral Breather Fitting Fitting, without Oil Cooler MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 9...

  • Page 12: Mtc-4208Xl Transfer Case Front Cover

    Exploded Views MTC-4208XL Transfer Case Front Cover 4007102a MM-0861 / Revised 06-22 Page 10 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 13 Locating Dowel Pin Front Output Shaft Elbow Needle Bearing Oil Spacer Helical Driven Gear Shim Fill Plug O-ring Magnetic Drain Plug Input Bearing Cage Yoke Sleeve Push Rod MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 11...

  • Page 14: Mtc-4208Xlev/Xlec Transfer Case Rear Cover

    Exploded Views MTC-4208XLEV/XLEC Transfer Case Rear Cover WITHOUT OIL COOLER XLEC VARIANT* 4011708c * If installing an EC kit on an EV, see TP-1923. MM-0861 / Revised 06-22 Page 12 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 15 Neutral Breather Fitting Pipe Plug, 1/4-18 NPT Speed Sensor Socket Head Bolt Capscrew and Washer P-Clamp Bearing Cups Angle Bracket Shims Lock Nut Bearing Cone Double Idler Gear MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 13...

  • Page 16: Mtc-4208Xlev/Xlec Transfer Case Front Cover

    Exploded Views MTC-4208XLEV/XLEC Transfer Case Front Cover 15 16 MM-0861 / Revised 06-22 Page 14 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 17 Input Bearing Cage Shift Fork Bearing Cage Capscrew and Washer Front Output Clutch Collar Input Oil Seal Magnetic Drain Plug Yoke Sleeve Fill Plug Cap Input Yoke MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 15...

  • Page 18: Mtc-4210X/Xp Transfer Case Rear Cover

    Exploded Views MTC-4210X/XP Transfer Case Rear Cover 4007388a MM-0861 / Revised 06-22 Page 16 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 19 * Vehicles not equipped with a transfer case neutral air control may be equipped with a neutral breather which allows the shift cavity to exhaust. On vehicles equipped with a neutral air control, the solenoid allows this cavity to exhaust. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022...

  • Page 20: Mtc-4210X/Xp Transfer Case Front Cover

    Exploded Views MTC-4210X/XP Transfer Case Front Cover FRONT 4007389a MM-0861 / Revised 06-22 Page 18 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 21 Drain Plug Male Fitting Oil Fill Plug Oil Pump Assembly Shift Cylinder Shim Shift Piston O-ring Input Bearing Cage Shipping Protector Bearing Cage Capscrew and Washer Lock Nut MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 19...

  • Page 22: Mtc-4210Xl Transfer Case Rear Cover

    Exploded Views MTC-4210XL Transfer Case Rear Cover 4007101a MM-0861 / Revised 06-22 Page 20 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 23 Lock Nut Blow-by Breather Oil Pump Inlet Tube Neutral Breather Tube Assembly, without Oil Cooler Shipping Protector Oil Pump Inlet Fitting Neutral Breather Fitting Fitting, without Oil Cooler MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 21...

  • Page 24: Mtc-4210Xl Transfer Case Front Cover

    Exploded Views MTC-4210XL Transfer Case Front Cover 22 23 18 19 4007102a MM-0861 / Revised 06-22 Page 22 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 25 Shim Front Output Clutch Collar O-ring Drain Plug Input Bearing Cage Magnetic Drain Plug Bearing Cage Capscrew and Washer Fill Plug Input Oil Seal Elbow Yoke Sleeve MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 23...

  • Page 26: Mtc-4210Xlev/Xlec Transfer Case Rear Cover

    Exploded Views MTC-4210XLEV/XLEC Transfer Case Rear Cover WITHOUT OIL COOLER 12 13 XLEC VARIANT* 4011708c * If installing an EC kit on an EV, see TP-1923. MM-0861 / Revised 06-22 Page 24 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 27 Neutral Breather Fitting Pipe Plug, 1/4-18 NPT Speed Sensor Socket Head Bolt Capscrew and Washer P-Clamp Bearing Cups Angle Bracket Shims Lock Nut Bearing Cone Double Idler Gear MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 25...

  • Page 28: Mtc-4210Xlev/Xlec Transfer Case Front Cover

    Exploded Views MTC-4210XLEV/XLEC Transfer Case Front Cover 4011709b MM-0861 / Revised 06-22 Page 26 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 29 Needle Bearing Input Bearing Cage Front Output Shaft Bearing Cage Capscrew and Washer Shift Fork Input Oil Seal Front Output Clutch Collar Yoke Sleeve Magnetic Drain Plug MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 27...

  • Page 30: Mtc-4213X Transfer Case Rear Cover

    Exploded Views MTC-4213X Transfer Case Rear Cover 10 7 4007103a MM-0861 / Revised 06-22 Page 28 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 31 Housing O-ring Rear Housing Neutral Breather Capscrew and Washer Neutral Breather Fitting Elbow Plug Breather Speed Sensor Capscrew and Washer Capscrew Switch Assembly Washer Spacer O-ring Shims MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 29...

  • Page 32: Mtc-4213X Transfer Case Front Cover

    Exploded Views MTC-4213X Transfer Case Front Cover FRONT 4007104a MM-0861 / Revised 06-22 Page 30 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 33 Shift Shaft Input Bearing Cage Front Output Shaft Input Oil Seal Helical Drive Gear Input Yoke Needle Bearing Flat Washer Drain Plug Lock Nut Oil Fill Plug Plug MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 31...

  • Page 34: Mtc-4208Xp And Mtc-4210Xp Declutch/Pto

    Exploded Views MTC-4208XP and MTC-4210XP Declutch/PTO 4000182a MM-0861 / Revised 06-22 Page 32 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 35 Connector Switch Assembly - Disengage (Optional) Shipping Protector Push Rod Shifter Piston O-ring O-ring Cover Plate Clutch Collar Shift Fork Bearing Assembly PTO Housing PTO Shaft Oil Seal Assembly MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 33...

  • Page 36: Model Nomenclature

    4 = Four-Shaft Design L = Rear Mount Pump* P = PTO Equipped* (space) = PTO Ready* *MTC-4208 and MTC-4210 only, not available for MTC-4213 4006921c Figure 3.1 MM-0861 / Revised 06-22 Page 34 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 37: Section 3: Introduction

    MTC-4210 Series are designed specifically for use in 4x4 power devices. Figure 3.7. vehicles (the MTC-4213 Series is designed specifically for 6x6) as part of the Meritor medium-duty 4x4 drive system. Figure 3.2. Optional switches for full-torque PTOs indicate full engagement or disengagement.
  • Page 38 OUTPUT GEAR SHAFT OUTPUT SHAFT SHAFT DOUBLE REAR IDLER GEAR OUTPUT SHAFT SHAFT FRONT OUTPUT SHAFT NEEDLE BEARING FRONT OUTPUT 4011711a SHAFT 4000184c Figure 3.5 Figure 3.7 MM-0861 / Revised 06-22 Page 36 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 39: Operation

    Engagement can be confirmed by hearing it, noticing improved vehicle performance, or observing the optional indicator light in the cab. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 37...
  • Page 40 ASSEMBLY OE COOLER LINE OIL PUMP CONNECTION TEE FITTING CROSSOVER PUMP INLET TUBE CONNECTION CONNECTION MTC-4208/10 XLEC DRIVER SIDE MOUNTED COOLER 4016827b 4014941d Figure 3.12 Figure 3.10 MM-0861 / Revised 06-22 Page 38 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 41 HIGH RANGE PORT NEUTRAL PORT (PTO-EQUIPPED ONLY) BLOW-BY BREATHER (IF EQUIPPED) LOW RANGE PORT 4000191d Figure 3.14 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 39...

  • Page 42: Section 4: Removal

    Drain and discard the oil correctly according to local and state environmental standards. Clean the magnetic drain plug. Figure 4.1, Figure 4.2, and Figure 4.3. MM-0861 / Revised 06-22 Page 40 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 43 PUMP INLET TUBE CONNECTION CONNECTION 13. Steam clean the outside of the transfer case to remove heavy amounts of dirt. 4014941d Figure 4.4 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 41...
  • Page 44 16. Attach a suitable lifting device to the eyebolts to lift the transfer case. Use suitable brackets to mount the case in the repair stand. Figure 4.7 and Figure 4.8. MM-0861 / Revised 06-22 Page 42 Copyright Meritor, Inc., 2022...

  • Page 45: Section 5: Disassembly

    If necessary, the input shaft may be removed without separating the transfer case halves. Once the transfer case is removed from the vehicle and the oil drained, Meritor recommends checking and recording the end play for the input shaft, output shafts, and idler gears before beginning this procedure.

  • Page 46: Disassemble The Transfer Case

    NOTE: The MTC-4213X has a two piece through shaft. Because of this design, only the forward half of the input shaft will be removed while the upper rear output shaft will remain in place. MM-0861 / Revised 06-22 Page 44 Copyright Meritor, Inc., 2022...
  • Page 47 INLET MTC-4208/10 XLEC VARIANT TUBE FITTING 4007121a PUMP OIL PUMP COVER OUTLET Figure 5.5 TO COOLER OIL PUMP CROSSOVER PUMP INLET TUBE CONNECTION CONNECTION 4014941d Figure 5.7 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 45...
  • Page 48 Remove the pump by applying forward pressure to the pump assembly and disengage the assembly from the oil pump drive pins located on the rear half on the input shaft. Figure 5.11. MM-0861 / Revised 06-22 Page 46 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 49 Skip this procedure. Remove the capscrews securing the input bearing cage and internal pump assembly, if equipped. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 47...
  • Page 50 Remove the shim pack. Figure 5.16. With the front input yoke still installed, remove the yoke nut, yoke, and front input bearing cage from the assembly. Figure 5.17. MM-0861 / Revised 06-22 Page 48 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 51 Remove the high and low shift fork, shift shaft, and clutch collar from the front case. Figure 5.22. Place eyebolts into the rear cover lift holes located at the top and bottom of the cover. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 49...
  • Page 52 Observe all hazard alerts provided by the press manufacturer. Support the shaft correctly. Death or serious personal injury and damage to components can result. Remove the rear nut and washer. Remove the yoke. MM-0861 / Revised 06-22 Page 50 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 53 Support the front input shaft and bearing cage assembly at 4210XLEV/XLEC, remove the needle bearing from the input the workbench. Figure 5.27. shaft. Figure 5.30 and Figure 5.31. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 51...
  • Page 54 Figure 5.33 Clean and save the shims so they can be used to measure the shim pack thickness during reassembly, if necessary. OIL INLET PORTS 4000201b Figure 5.32 MM-0861 / Revised 06-22 Page 52 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 55: Section 6: Prepare Parts For Assembly

    • Before steam cleaning the transfer case, close or put a cover over all openings in the case. • Remove any remaining silicone sealant from the transfer case halves using a suitable scraper or wire wheel. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 53...

  • Page 56: Dry Parts

    • Bright wear marks appear on the outer surface of the roller For more detailed information about parts inspection, refer to cage. TP-0445, Meritor Parts Failure Analysis. To obtain this publication, refer to the Service Notes page on the front inside cover of this manual.

  • Page 57: Repair Or Replace Parts

    A bent axle beam reduces axle strength, affects vehicle SPALLING AND operation, and voids Meritor’s warranty. Death or serious personal FLAKING injury and damage to components can result. Replace worn or damaged parts of a transfer case assembly.

  • Page 58: Applying Adhesive And Silicone Gasket Material

    Fasteners The silicone gasket products listed in the table below or their Removing Fasteners Secured with Adhesive equivalent can be used on Meritor components. If it is difficult to remove fasteners secured with Dri-Loc , Meritor ®...

  • Page 59: Helical Gears

    • A crack in the root of a tooth or along the tooth flank. CRACK 4000295a Figure 6.9 • Deep gouges or metal transfer along the input gear journals. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 57...

  • Page 60: Shafts

    • Cracked or missing tangs on the shift fork arms. • Chipped or cracked shifting splines on the shift collar. • Cracks or deep gouges on the shift shaft. MM-0861 / Revised 06-22 Page 58 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 61: Oil And Lubrication System

    Once the transfer case has been installed on the vehicle, verify the pump pressure is correct. Refer to the pump pressure check instructions in the final assembly procedures MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 59...

  • Page 62: Section 7: Assembly

    CAUTION CLUTCH COLLAR BEARING Although Meritor does not recommend its use in transfer cases, if a formed-in-place gasket is used for repairs, extreme caution must be exercised to prevent compound from entering bearings, HOLDING FIXTURE oil galleries, and passages or tapped holes. All beads must be TOOL 905473-140 kept smaller than 0.100”...
  • Page 63 Assembly 10. Lubricate the output shaft threads with SAE Grade full- synthetic 40W or 50W oil, Meritor specification O-81. NEEDLE BEARING 11. Install the washer and the locknut onto the shaft. Tighten the ASSEMBLY locknut to 700-900 lb-ft (949-1220 Nm). Figure 7.5.
  • Page 64 Place the large o-ring around the groove on the bearing cage. Install the internal oil pump using the following procedure. Figure 7.7. a. Pack lithium-complex grease, Meritor specification O-668, into the pump oil inlet port before assembling the oil pump to the input bearing cage.
  • Page 65 Install the needle bearing on the input shaft. NOTE: Use care when installing the input bearing cage to prevent Figure 7.10. damage to the o-ring. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 63...

  • Page 66: Assemble The Upper Rear Output Shaft (Mtc-4213X Only)

    Use SAE Grade 10. Install the washer and yoke nut. Tighten the yoke nut to 700- full-synthetic 40W or 50W oil, Meritor specification O-81. 900 lb-ft (949-1220 Nm). Use a mallet or press and sleeve to install the bearing cups into the bore until correctly seated.

  • Page 67: Install The Front Input Shaft, Input Bearing Cage, And Internal Oil Pump Assembly Installation (If Equipped)

    Rotate the transfer case so the front is facing UPWARD. NOTE: All shaft bearing end plays must be determined before final assembly. Refer to "End Play Check and Adjustment" on page 67. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 65...

  • Page 68: Install The Upper Rear Output Shaft (Mtc-4213X Only)

    Ensure the bar stock does not rest under the transfer case mounting flange, but only supports the gear and shaft assembly. Figure 7.19. MM-0861 / Revised 06-22 Page 66 Copyright Meritor, Inc., 2022...

  • Page 69: End Play Check And Adjustment

    Use new shims to obtain the same thickness as the original shim pack. This will be the starting shim pack thickness to use when setting the respective shaft’s end play. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022...

  • Page 70: Front Output Shaft End Play (All Models)

    Before installing the yoke, clean the splines of old silastic. Apply a 1/8” (3.175 mm) bead of RTV 732 sealant 360 degrees around the underside of the washer. Figure 7.25. MM-0861 / Revised 06-22 Page 68 Copyright Meritor, Inc., 2022...

  • Page 71: Mtc-4213X Rear Output Shaft End Play

    700-900 lb-ft (949-1220 Nm). Place the rear cover on the bench to measure bearing end play. Refer to the bearing cup and shim installation procedures in this section. Figure 7.27. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 69...
  • Page 72 Recheck the end play. Tighten the capscrews to 85-115 lb-ft (115-156 Nm). Recheck the input shaft bearing end play. Adjust the end play as necessary. MM-0861 / Revised 06-22 Page 70 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 73: Final Assembly

    Table B: Shim Selection Example Lubricate and install the o-ring into the rear cover push rod journal. Use a light coat of lithium-based grease, Meritor Initial specification O-668, prior to cover installation. Figure 7.30.
  • Page 74 Repeat the adjustment procedures as required. High and Low Shifter OUTER SHIFT PISTON Grease all o-ring seals. Use a light coat of lithium-based grease, Meritor specification O-668. Refer to Figure 7.31 for shifter component arrangement. HIGH RANGE PORT 4000192a RANGE PORT Figure 7.33...
  • Page 75 Position the yoke on a 5” (127 mm) spacer on a workbench. 5" (127 MM) Use a dead-blow hammer and the appropriate driver to install SPACER the sleeve into the yoke. Figure 7.36. Figure 7.36 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 73...
  • Page 76 Output Shaft Oil Seal and Yoke Use a feeler gauge to check the seal gap. The seal is correctly All Models: Install the input seal and sleeve using Meritor kits installed if the gap is less than 0.005” (0.127 mm) around the 2728T1 and 2728T2 respectively.
  • Page 77 Leave 3/16” (4.763 mm) of the drive pins Use a 5/8” socket and tighten the housing bolts in a criss- extending from the input shaft. Figure 7.42. cross pattern to 60-75 lb-ft (101 Nm). MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 75...
  • Page 78 12. Use a 7/16” socket and tighten the bolts in a criss-cross pattern to 10-13 lb-ft (14-18 Nm). Breather, Speed Sensor and Plugs If necessary, install the breather into the rear cover. Figure 7.47. MM-0861 / Revised 06-22 Page 76 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 79: Transfer Case Shifting Check

    Remove the air pressure. Apply 60 psi (4.14 bar) or greater of air pressure to the high- range shaft air port. Figure 7.50. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 77...

  • Page 80: Transfer Case Assembly Test

    If the pressure decreases by more than 2 psi (0.14 bar) in 10 minutes: Check for external leaks at the fittings. Correct the leakage problem and retest. Reinstall the breather assembly. MM-0861 / Revised 06-22 Page 78 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 81: Section 8: Power Take-Off (Pto)

    Hazard Alert Messages This section provides instructions on installing a power take-off (PTO) assembly onto Meritor MTC-4208 and MTC-4210 transfer cases using Kit 2540. Refer to Table D and Figure 8.1. Refer to Read and observe all hazard alert messages in this publication.

  • Page 82: Exploded View

    O-ring, 1.46” (37 mm) Diameter Special Screw O-ring, 1.80” (46 mm) Diameter Capscrew, 1.25” (32 mm) Long Cover Plate Capscrew, 5.75” (146 mm) Long Switch Assembly, Standard Washer (Optional) MM-0861 / Revised 06-22 Page 80 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 83: Remove The Transfer Case Rear Access Cover

    Technical Bulletin TP-0708 - Removing the External Oil Pump and Installing the Internal Oil Pump for the correct kit and instructions. Clean the PTO mounting surface to remove all sealant. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 81...

  • Page 84: Exploded View

    Capscrew, 1.25” (32 mm) Long Capscrew, 5.75” (146 mm) Long Yoke Washer, Yoke Mounting Lock Nut, Yoke Mounting Switch and Connector Assembly Dowel Pin * Kit 2540 component MM-0861 / Revised 06-22 Page 82 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 85: Install The Yoke Onto The Pto

    (227-680 kg) to install a Meritor yoke, spline code RAI, onto the PTO shaft. Figure 8.2. A Meritor yoke with the spline code “RAI” must be installed onto the PTO. For yoke options, refer to Table E and Figure 8.3.

  • Page 86: Install The Pto Onto The Transfer Case

    Apply 90 psi (6.2 bar) of air pressure. Check for leaks in the PTO air control line. Cycle the air control pressure. Follow the procedures below to verify the PTO clutch engages correctly. MM-0861 / Revised 06-22 Page 84 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 87: Test The Transfer Case With The Pto Assembly Installed

    Once the PTO has been removed according to the procedure in Section 5, use the following procedure for disassembly. WARNING Take care when removing the spring-loaded PTO cap. Serious personal injury and damage to components can result. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 85...
  • Page 88 200°F (93°C) using an oven or inductive k. Lightly lubricate all parts with SAE Grade full-synthetic 40W or bearing heater and install it onto the shaft. Figure 8.10. 50W oil, Meritor specification O-81. l. Install the 1/4-20 screws using Loctite 242 sealant. Tighten ®...
  • Page 89 PTO or proportional differential lockout assemblies. a. With the correct fitting installed into the air control port, apply a pressure of 90 psi (6.2 bar). b. Shut off the air supply. MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 87...

  • Page 90: Section 9: Installation

    Connect any switch or speed sensor wiring. Fill the transfer case with the correct quantity of specified lubricant. Refer to "Lubrication and Maintenance" on page 97. MM-0861 / Revised 06-22 Page 88 Copyright Meritor, Inc., 2022 Printed in USA...
  • Page 91 4007121a 4012334a Figure 9.2 Figure 9.3 MTC-4208/10 XLEC VARIANT PUMP OIL PUMP COVER OUTLET TO COOLER OIL PUMP CROSSOVER PUMP INLET TUBE CONNECTION CONNECTION 4014941d Figure 9.4 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 89...
  • Page 92 Make certain there is no tension applied to the crossover tube. Make certain there is no tension applied to the crossover tube once the fasteners have been tightened. tube once the fasteners have been tightened. MM-0861 / Revised 06-22 Page 90 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 93: Section 10: Troubleshooting

    2. Check the transfer case and amount of oil. for air leaks. Continue to next page. Road test the vehicle, then check for leaks. Return vehicle to service. 4001525b Figure 10.1 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 91...
  • Page 94 NOTE: An incorrect installation can cause a seal leak. Road test the vehicle, then check for leaks. Return vehicle to service. Check the transfer case for leaks. 4001526b Figure 10.2 MM-0861 / Revised 06-22 Page 92 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 95: Excessive Noise And Vibration Diagnostics

    Problem transfer case shafts for determine if corrected? excessive wear. Repair as noise/vibration necessary. is still present. Return the vehicle to service. 4001527b Figure 10.3 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 93...

  • Page 96: Pto Does Not Engage/Disengage Diagnostics

    Reassemble and install the PTO on the transfer case. Road test the vehicle to confirm the problem is corrected. Return the vehicle to service. 4001528d Figure 10.4 MM-0861 / Revised 06-22 Page 94 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 97: Front Axle Declutch Does Not Engage/Disengage Diagnostics

    Repair all damaged components. Reinstall the transfer case onto the vehicle. Road test the vehicle to confirm the problem is corrected. Return the vehicle to service. 4001529d Figure 10.5 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 95...

  • Page 98: High/Low Gear Shifting Diagnostics

    Reassemble and check the transfer case shifts correctly. 866-OnTrac1 (668-7221). Reinstall transfer case Contact OnTrac™ Problem in vehicle and return Customer Call Center at fixed? vehicle to service. 866-OnTrac1 (668-7221). 4001530c Figure 10.6 MM-0861 / Revised 06-22 Page 96 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 99: Section 11: Lubrication And Maintenance

    Lubrication. To obtain a copy of this publication or access it on components. Meritor’s website, refer to the Service Notes page on the inside front cover of this manual. Petroleum-Base and Multi-Viscosity Oils...
  • Page 100 NEUTRAL PORT (PTO-EQUIPPED ONLY) BREATHER Meritor has released the multiple-lip seal (MLS) for use in the INPUT POSITION ONLY on the MTC-4208, MTC-4210, and MTC- 4213 transfer cases. The multiple-lip seal is compatible with the BLOW-BY current input shaft seal and can be used in service.

  • Page 101: Oil Fill Procedure

    FRONT OUTPUT DRAIN FILL YOKE NOTE: Meritor recommends the oil cooler lines should be routed PLUG PLUG to prevent oil flow back into the transfer case sump. This can be MTC-4208X/XP, MTC-4210X/XP, AND MTC-4213X 4006338f accomplished by routing lines with a P-trap configuration for both the oil cooler inlet and outlet lines.

  • Page 102: Pump Priming And Pressure Check Procedure

    Install a pressure gauge to the diagnostic port using a suitable Figure 11.7 adapter. For XL/XLEV use the diagnostic port shown in Figure 11.6. For XLEC use the diagnostic port shown in Figure 11.7. MM-0861 / Revised 06-22 Page 100 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 103: Transfer Case Inspection

    Damage to components can result. Call the after extended time high speed road trips. Areas to inspect include: Meritor OnTrac™ Customer Call Center at 866-668-7221 for assistance. • Cooler lines and fittings NOTE: System pressure can be in excess of 75 psi (5.17 bar).
  • Page 104 2 Do not use multi-viscosity oils. MTC-4208XP 13.25 (6.27) 3 Meritor-approved full-synthetic oil for Meritor manual MTC-4210X 13.25 (6.27) transmissions is also approved for Meritor transfer cases. Use MTC-4210XLEC 13.50 (6.39) synthetic oil only if the transfer case was initially filled with synthetic oil. MTC-4210XLEV 12.50 (5.92)

  • Page 105: Section 12: Torque Specifications

    Specifications Torque Specifications Standard MTC-4213X, MTC-4208XP, and MTC-4210XP OIL COOLER READY MODEL STANDARD MODEL MTC-4213X MTC-4208XP AND MTC-4210XP FRONT FRONT 4007123a Figure 12.1 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 103...
  • Page 106 582 threadlocker to pipe threads ® 2 Apply Loctite 592 threadlocker ® 3 Apply Loctite ® 242 threadlocker 4 Apply Loctite 518 threadlocker to the first three threads ® MM-0861 / Revised 06-22 Page 104 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 107: Standard Mtc-4208X/Xl/Xlev And Mtc-4210X/Xl/Xlev

    Specifications Standard MTC-4208X/XL/XLEV and MTC-4210X/XL/XLEV MTC-4208X AND MTC-4210X MTC-4208XL AND MTC-4210XL 4007200a Figure 12.2 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 105...
  • Page 108 Weight lbs (kg) Figure 12.3 Base Model 670 (304) 65 (29.5) NOTE: The transfer case filled with lubricant weighs approximately 750 lbs (340.2 kg) without the PTO. MM-0861 / Revised 06-22 Page 106 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 109: Section 13: Vehicle Towing Instructions

    Follow towing procedures recommended by Meritor to prevent internal damage to the transfer case. Meritor recommends using one of the two methods below when towing to prevent damage to the transfer case. NOTE: For complete towing information and instructions on axle shaft removal, refer to Technical Bulletin TP-9579 - Driver Instruction Kit.

  • Page 110: Section 14: Tools

    The following section provides details of tooling to facilitate service of the transfer case. Service tools may be manufactured using these drawings or contact Meritor for a price and delivery quotation. The manufacture of these tools should be carried out by professional machinists and certified welders, following typical good workmanship procedures and safe practices.

  • Page 111: Bearing Cone Driver (905473-92)

    DIA. DIA. 1.00 0.13 KNURL X 45° 0.50 4.00 4007159a Figure 14.2 Bearing Driver (4FI20-27110-000008) Assembled Tool - 2 pieces: 4FI20-27110-000008-D01 4FI20-27110-000008-D02 0.568 1.560 4012346a Figure 14.3 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 109...
  • Page 112 4140 PRE-HARDENED Ø2.108 Ø1.608 0.250 1.375 0.13X45° 3.125 3/16 DRILL 3.625 THRU BOTH SIDES (HOLE FOR ROLL PIN) 0.06X45° R0.250 SEE TOOL ASSEMBLY INSTRUCTIONS 4012354a Figure 14.5 MM-0861 / Revised 06-22 Page 110 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 113: Bearing Cone Driver (905473-82)

    ø 3.25 DIA. DIA. DIA. 0.03 R 0.12 R 0.03 X 45° 0.90 (2) PLCS. KNURL NOTE: Not available from Meritor. 4007160a Figure 14.6 Bearing Cup Driver (910203-36) 3.65 0.09 RAD. TYP . MIN. UNDERCUT 1.76 3.980 4.810 4.450 3.48 3.978...

  • Page 114: Bearing Cup Driver (4Fi20-27110-000007)

    0.875 0.63 BEARING CUP DRIVER FOR DRILL AND CUPS JM207010 AND 33821 C’BORE FOR Ø3.063 1/2-30 SDC Ø3.454 HR SCR 4012345a SEE TOOL ASSEMBLY INSTRUCTIONS Figure 14.9 MM-0861 / Revised 06-22 Page 112 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 115: Bearing Cup Driver (910203-37)

    0.09 RAD. TYP . MIN. UNDERCUT 4.997 3.980 4.980 4.637 3.48 3.978 4.976 4.995 DIA. DIA. DIA. DIA. DIA. DIA. 45° 1.09 0.250 1.56 1.50 4.34 4007158a Figure 14.10 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 113...

  • Page 116: Pto Bearing Cone Driver

    Tools PTO Bearing Cone Driver 8.00 4.00 3.500 3.000 0.250 R 0.38 0.38 5.375 4.50 0.44 4007162a Figure 14.11 MM-0861 / Revised 06-22 Page 114 Copyright Meritor, Inc., 2022 Printed in USA...

  • Page 117: Modified Bearing Cup Puller

    Remove – cup contact not needed Grind the corner Disassemble and for clearance turn the fingers out (both sides) 4012353a Figure 14.12 MM-0861 / Revised 06-22 Printed in USA Copyright Meritor, Inc., 2022 Page 115...
  • Page 118 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. 2135 West Maple Road Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the information presented or to discontinue the production of parts described at any time. Troy, MI 48084 USA...

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