Meritor FAT-30 GEN 2 Maintenance Manual

Auxiliary transmission

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MAINTENANCE MANUAL MM-19112

MERITOR FAT-30

GEN 2 AUXILIARY TRANSMISSION

™

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Page 1 MAINTENANCE MANUAL MM-19112 MERITOR FAT-30 GEN 2 AUXILIARY TRANSMISSION ™...
Page 2: About This Manual
If Parts, Tools, and Supplies are Speciﬁ ed in this Manual Contact Meritor’s Commercial Vehicle Aftermarket at 888-725-9355. For assistance with parts, you may also contact the Meritor Parts Center in Florence, KY at CustCareCntr.Florence@Meritor.com or 859-525-3500. 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.
Page 3: Table Of Contents
Section 4: Shifting Instructions ......11 Automatic Transmission ........11 Manual Transmission ........11 Section 5: Diagnostics ........12 Pneumatic Diagnostics ........12 Electrical Diagnostics ........13 High Temperature ..........17 MM-19112 / Issued 04-21 Printed in USA Copyright Meritor, Inc., 2021 Page i...
Page 5: Section 1: Safety Information
CAUTION Indicates a hazardous situation or unsafe practice which, if not avoided, could result in injury or damage to components. MM-19112 / Issued 04-21 Printed in USA Copyright Meritor, Inc., 2021 Page 1...
Page 6: Section 2: Exploded Views
Exploded Views EXPLODED VIEWS Transfer Case 4018154a MM-19112 / Issued 04-21 Page 2 Copyright Meritor, Inc., 2021 Printed in USA...
Page 7 Spring Snap Ring Ball Wave Spring Needle Bearing Snap Ring Housing Shim, .005 O-ring Shim, .007 Ring Gear 101T Shim, .020 Rear Main Carrier Sun Gear 54T MM-19112 / Issued 04-21 Printed in USA Copyright Meritor, Inc., 2021 Page 3...
Page 8: Planetary Carrier - 17T
Exploded Views Planetary Carrier - 17T 4018152a Item Description Spacer Gear 17T Needle Bearing Plug Snap Ring Dowel Pin Set Screw Planetary Carrier MM-19112 / Issued 04-21 Page 4 Copyright Meritor, Inc., 2021 Printed in USA...
Page 9: Planetary Carrier - 23T
Exploded Views Planetary Carrier - 23T 4018151a Item Description Spacer Gear 23T Needle Bearing Plug Snap Ring Dowel Pin Set Screw Planetary Carrier MM-19112 / Issued 04-21 Printed in USA Copyright Meritor, Inc., 2021 Page 5...
Page 10: Shifter
Shift Cylinder Tube Indicator Switch O-ring O-ring Piston Dowel Pin Adapter Tube Bolt Capscrew Shift Fork Washer Adapter Tube Piston Shift Cylinder Tube O-ring Stud Shift Cylinder Tube MM-19112 / Issued 04-21 Page 6 Copyright Meritor, Inc., 2021 Printed in USA...
Page 11: Remote Oil Filter Kit
Exploded Views Remote Oil Filter Kit 4018156a Item Description Housing Nipple Straight Oil Filter MM-19112 / Issued 04-21 Printed in USA Copyright Meritor, Inc., 2021 Page 7...
Page 12: External Components
Exploded Views External Components 4018155a MM-19112 / Issued 04-21 Page 8 Copyright Meritor, Inc., 2021 Printed in USA...
Page 13 Exploded Views Item Description Straight Oil Strainer Hose Assembly Washer Bolt Straight Breather Vent Plug Flat Washer Capscrew Plug, 3/4” Plug, 1/2” Hex Head Companion Flange MM-19112 / Issued 04-21 Printed in USA Copyright Meritor, Inc., 2021 Page 9...
Page 14: Section 3: Introduction
Description The Meritor FAT-30 is an extreme-duty auxiliary transmission designed to suit the needs of a variety of and on- and off-highway applications including logging, mining, heavy haul, oil ﬁ eld and military. The FAT-30™ auxiliary transmission is rated for 30,000 ft-lbs (40,675 Nm) of input torque.
Page 15: Section 4: Shifting Instructions
Shifting Procedure 3. Shift the FAT-30 Gen 2 into the desired gear. The selected gear indicator will ﬂ ash until positive engagement is 1. Stop the vehicle and apply the parking brake.
Page 16: Section 5: Diagnostics
If it is determined that the proper signals are being sent, manually apply air pressure to the desired 1/4 NPT port and conﬁ rm positive shift engagement. If the desired range cannot be achieved with an external air source, contact Meritor at 866-668-7221 for further assistance. Table B: Pneumatic Diagnostics...
Page 17: Electrical Diagnostics
12 PIN CONNECTOR .39" (10mm) SWITCH MATRIX 12 PIN CONNECTOR POSITION SOLENOIDS 3.72" A&C (94.5mm) B&D 5.35" M4 FH SCREW (136 mm) 4016789b 4Plcs TYP Figure 5.2 Wiring Diagram MM-19112 / Issued 04-21 Printed in USA Copyright Meritor, Inc., 2021 Page 13...
Page 18 Solenoid C Solenoid D Figure 5.3 Rear View of Connector Signal from parking brake NOTE: If your speciﬁ c switch is not listed, contact Meritor at 866- Allison wire 123 668-7221 for further assistance. Neutral indicator switch Table C: Mack Wiring Harness Key (Eaton)
Page 19 Neutral indicator switch Low indicator switch Low indicator switch Direct indicator switch Direct indicator switch High indicator switch High indicator switch Battery negative (-) Battery negative (-) (16579) MM-19112 / Issued 04-21 Printed in USA Copyright Meritor, Inc., 2021 Page 15...
Page 20 3-SPEED PANEL MOUNT PARK BRAKE ALLISON 123 LINE DRAWING NUMBER 429-0356-S TRANS NEUTRAL SWITCH TRANS LOW SWITCH TRANS DIRECT SWITCH TRANS HIGH SWITCH 4016889a CHASSIS GROUND Figure 5.6 MM-19112 / Issued 04-21 Page 16 Copyright Meritor, Inc., 2021 Printed in USA...
Page 21: High Temperature
• Excessive ambient/outside temperature in which the auxiliary transmission is operating • Excessive overdrive operation • Excessive stationary operation where air ﬂ ow is limited • Excessive high horsepower / RPM operation MM-19112 / Issued 04-21 Printed in USA Copyright Meritor, Inc., 2021 Page 17...
Page 22: Section 6: Lubrication & Maintenance
WITH CONNECTOR #12162193) OIL FILL PLUG OIL LEVEL SIGHT PLUG (FILL TO CENTER) 1/2 NPT PROVISION FOR TEMPERATURE SENSOR OIL DRAIN PLUG 4016792b Figure 6.1 Lubrication Maintenance Locations MM-19112 / Issued 04-21 Page 18 Copyright Meritor, Inc., 2021 Printed in USA...
Page 23: Filling Oil
EXPOSED TO ADEQUATE AIR FLOW AND CAN BE REGULARLY CLEANED. OUTLET OIL COOLER INLET 5/8 (-10) HOSE MINIMUM REMOTE FILTER 4016793a Figure 6.2 Transfer Case Top View MM-19112 / Issued 04-21 Printed in USA Copyright Meritor, Inc., 2021 Page 19...
Page 24: Section 7: Seal Replacement
Keep the jam nut in position on the speed sensor to mark/maintain the depth of installation. Figure 7.4. Speed Sensor O-ring Yoke Washer 4018169a 4018163a Figure 7.4 Figure 7.1 MM-19112 / Issued 04-21 Page 20 Copyright Meritor, Inc., 2021 Printed in USA...
Page 25 8. Once the seal has been removed, verify the ball is the groove Seal and the thin o-ring at the base of the splines is still in place. Driver If this o-ring is missing or dislodged, contact the Meritor OnTrac™ Customer Service Center at 866-668-7221 for assistance. Figure 7.6. O-ring...
Page 26 5. Install the yoke, a new o-ring, and the washer on the output shaft. Figure 7.11. Rear Output Yoke O-ring 4018168a Figure 7.13 Washer 4018165a Figure 7.11 MM-19112 / Issued 04-21 Page 22 Copyright Meritor, Inc., 2021 Printed in USA...
Page 27: Input Seal Replacement
5. Install a new sealing o-ring on the yoke splines. 6. Install the washer. 7. Install a new yoke nut and tighten it to 500-600 lb-ft (678- 913 Nm). 8. Verify the oil level is correct. MM-19112 / Issued 04-21 Printed in USA Copyright Meritor, Inc., 2021 Page 23...
Page 28: Section 8: Vehicle Towing Instructions
The oil pump is input shaft driven, meaning, the input shaft must rotate to provide lubricant to the internal rotating components. Meritor recommends using one of the methods below when towing to prevent damage to the auxiliary transmission. METHOD 1 (PREFERRED) Remove the driveline from the FAT-30 output to the rear drive axles.
Page 29: Section 9: Tools
Tools TOOLS Seal Driver 3.010” 5.000” Ø ±0.005 5.188” 4018157a Figure 9.1 MM-19112 / Issued 04-21 Printed in USA Copyright Meritor, Inc., 2021 Page 25...
Page 32 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...