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TECHNICAL BULLETIN TP-1923
MTC-4208XL/XLEV and MTC-4210XL/XLEV
TRANSFER CASE OPTIMIZED-PERFORMANCE
OIL PUMP CONVERSION PROCEDURE
Hazard Alert Messages
Read and observe all hazard alert messages in this publication.
DANGER
Indicates imminent danger. Failure to follow this instruction will
result in death or serious injury.
WARNING
Indicates a possibly impending danger. Failure to follow this
instruction can result in death or serious injury.
CAUTION
Indicates a hazardous situation or unsafe practice which, if not
avoided, could result in injury or damage to components.
How to Obtain Additional Maintenance,
Service and Product Information
Refer to Maintenance Manual MM-0861 - MTC-4208X/XL/XP/
XLEV, MTC-4210X/XL/XP/XLEV, and MTC-4213X Series Transfer
Cases. To obtain this publication, visit Literature on Demand at
meritor.com.
Contact the Meritor OnTrac™ Customer
Service Center
If you have questions about the procedures in this bulletin,
™
contact the Meritor OnTrac
Customer Service Center at 866-
668-7221 (US and Canada) between 7:30 AM and 10:00 PM ET
Monday through Friday, and between 9:00 AM and 6:00 PM ET
on Saturday; 001-800-889-1834 (Mexico); or visit our website:
https://www.meritor.com/warranty#OnTracSC.
Printed in USA
Purpose
This bulletin provides instructions to convert the rear oil pump on
Meritor MTC-4208XL/XLEV and MTC-4210XL/XLEV model transfer
cases to an optimized-performance oil pump.
Meritor recommends consulting with the vehicle OEM prior to
converting the MTC4208/10XLEV to the MTC4208/10XLEC to
verify the transfer case oil cooler meets the required heat exchange
rate.
Safety Precautions
Before performing the procedures in this publication, read and
understand the following safety precautions.
Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Support the vehicle with safety stands.
NEVER work under a vehicle supported only by jacks. Jacks can
slip and fall over. Failure to use safety stands can result in death
or serious personal injury and damage to components.
To prevent eye injury, always wear eye protection when performing
vehicle maintenance or service.
Take care when using Loctite
injury. Read the manufacturer's instructions before using this
product. Follow the instructions carefully to prevent irritation to
the eyes and skin. If Loctite
follow the manufacturer's emergency procedures and get
checked by a physician as soon as possible.
Copyright Meritor, Inc., 2021
DANGER
WARNING
WARNING
®
adhesive to avoid serious personal
®
adhesive material gets into the eyes,
TP-1923 / Revised 11-21
Page 1
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Summary of Contents for Meritor MTC-4208XL
- Page 1 Meritor MTC-4208XL/XLEV and MTC-4210XL/XLEV model transfer cases to an optimized-performance oil pump. DANGER Meritor recommends consulting with the vehicle OEM prior to Indicates imminent danger. Failure to follow this instruction will converting the MTC4208/10XLEV to the MTC4208/10XLEC to result in death or serious injury.
- Page 2 The parts in KIT-2967 are used in this conversion procedure. Figure 1. Lock Nut NL-24-1 Straight Reducer 3/4" x 1/2" 2206-Z-1742 NPT Male Cap 1/2" NPT Female 2206-Z-1743 4015057b Figure 1 TP-1923 / Revised 11-21 Page 2 Copyright Meritor, Inc., 2021 Printed in USA...
- Page 3 Figure 3. PUMP HOUSING WASHER PUMP HOUSING PUMP BOLT COVER 4007122a Figure 3 TP-1923 / Revised 11-21 Printed in USA Copyright Meritor, Inc., 2021 Page 3...
- Page 4 10. Apply Loctite ® 242 threadlocker or equivalent to the pump FITTING 4014939c cover capscrew threads if the new capscrews do not already Figure 10 have an adhesive patch. TP-1923 / Revised 11-21 Page 4 Copyright Meritor, Inc., 2021 Printed in USA...
- Page 5 NOTE: The P-clamp bracket is intended to support the crossover tube. Make certain there is no tension applied to the crossover tube once the fasteners have been tightened. TP-1923 / Revised 11-21 Printed in USA Copyright Meritor, Inc., 2021 Page 5...
- Page 6 4. Connect the oil pump crossover tube from the front case to the pump outlet fi tting on the rear case half. Tighten the tube nut to 20 lb-ft (27 Nm). Figure 15. TP-1923 / Revised 11-21 Page 6 Copyright Meritor, Inc., 2021 Printed in USA...
- Page 7 Figure 16 Figure 17 1. Refi ll as follows: • Use Meritor-approved lubricant, full-synthetic 50W or 40W oil. Refer to publication TP-90114 - Transmission Lubricant Specifi cations for a list of approved distributors. • Fill the transfer case to the bottom of the fi ll adapter.
- Page 8 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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