Meritor MTC4208XL-EVO Transfer Case Parts Manual

Meritor MTC4208XL-EVO Transfer Case Parts ManualPro Gear Meritor MTC4208XL-EVO Transfer Case Parts Manual to assist in identifying yourMeritor unit. If you need any assistance identifying the correct transfer case unit foryour truck and equipment, contact your Meritor replacement part specialists at Pro Gear andTransmission.Pro Gear Transmission has same day shipping and 1000’s of products in stock and ready toship internationally for your next project.For parts or service contact the Meritor specialists at Pro Gear & Transmission, Inc.1 (877) 776-4600(407) 872-1901parts@eprogear.com

PB-0910Issued 4/09MTC4208X / XPTransfer CaseNOTE: The MTC-4208X/XP transfer case models are backward-compatible with MTC-4208 transfer case specifications.There are no changes to the oil cooler interface points with these models. However, the exterior geometry of the housinghas changed, which potentially impacts clearances to surrounding components. In addition, the previous models cannotbe used in place of the new models in applications with “engage-on-the fly” systems or mid-ship pumps. Refer toMaintenance Manual MM-0146, Transfer Cases, for more information.

MTC4208 X / XP - Front

MTC4208 X / XP - Rear

MTC4208 X / XP - PTO

MTC-4208X / XP TRANSFER crew - Sensor RetainerWasher - Sensor RetainerCover - PTOLocknutLocknut - Rear Input ShaftWasher - HardenedCover - Transfer Case RearShipping Protector - PlugShift CylinderO-Ring - Shift PistonPiston - Shift (Outer)Piston - ShiftPiston - Shift (Inner)O-RingO-RingO-RingBushing - 112211Part 922206-Q-1447Neutral BreatherBlow-By BreatherSpeed SensorBearing CupBearing CupGear - IdlerBearing ConeBearing ConeMagnet - CeramicEngagement 97-K-67713237-W-1167Oil Seal - Rear Output1Yoke - Rear OutputWasher - FlatPTO Assembly - OptionalDriven Gear and Rear Output ShaftRing - SnapShaft - ShiftShaft - InputPlug - Special OrificeCapscrew - Shift ForkCapscrew - Shift ForkShift ForkShift ForkGear - Helical Drive, High RangeClutch Collar - High and LowGear - Helical Drive, Low RangeRing - SnapPin - Locating DowelTube Assembly - Inlet OilElbow - MaleBreather AssemblyOil Pump AssemblySpring - Pressure ReliefCage - Input BearingO-Ring - Input Bearing Cage1411211111111111211111111R945007Rap or RCESpline W-14795-X-13274CommentsM45 x 1.5 thd2.25"-12 thd2.28" ID x 3.25" OD x .32" wide1.459" ID x .208" thick.984" ID x .139" thick.734" ID x .139" thick1.17" ID x .139" thickNot for use with vehicles equippedwith Neutral AirlineOptional2.625" ID cone2.4375" ID one4.8125" OD cup5.00" OD cupOptional. Do not use with special screw(41-X-1022) and washer (1229-U-1503).3.25" ID x 4.25" OD x .86" wide2-3/8" - 46 spline (slinger optional)1.79"ID x 3.00" OD x .19" wideOptional (KIT 2540).689" IDService with KIT 2590.090" orifice7/16" x 1.5"3/8" x 1.5"Input shaftFront outputUse with shaft 3297-H-1542.375 dia. x 1.00" longOil cooler ready3/4"-14NPTF / 1-1/16"-12UNC-2A3/8"-18 NPTUse A-3226-Z-1482 input cageOil cooler ready7.483" x .139" thick

MTC-4208X / XP TRANSFER w - Bearing CageWasher - FlatOil Seal - InputFitting Assy - Tube AdapterValve - ReliefWasher - Oil Pump CapscrewCapscrew - Oil PumpElbowPlug - Oil FillPlugYoke - Front OutputQty7711166114112111111Asreqd6061Seal - Front Output OilPlug - DrainPush RodFront T-Case HalfClutch Collar - Front OutputSpringShaft - Front OutputGear - Helical Driven - Front OutputShim - .003"Shim - .005"Shim - .010"Shim - .0197"Shim - .003"Shim - .005"Shim - .010"PlugYoke - Input6263646566Male Connector - Oil CoolerLoop TubeNeedle BearingSeal - PTOYoke - PTO11111717273747576Bolt/CapscrewWasher - FlatBolt/Capscrew - T-case HousingWasher - Flat - T-case HousingCapscrew - PTO (short)Capscrew - PTO (long)29378862***See Yokes Page 950515253545556575959aAsreqd11Part -26Rap or RCESpline Code 12803-R-3112P-28Rap or RCESpline Code ***2206-E-1513A-2296-Q-11611228-P-1654R945008RAI SplineCode 2S-2748-25Comments1/2"-13 thd x 1.75".53" ID x .88" OD x .09" wide3.25" ID x 4.25" OD x .86 long3/4"-14 NPT.04" ID x .62" OD x .06" wideM8 x 1.253/8"-NPT / 3/8"-18 NPT3/4"-14 NPT square socket3/8"-18 NPT square socket2-3/8"-46T spline (slinger opt.)3.25" ID x 4.25" OD x .86" wide3/4"-14 NPT square socketOil cooler readyInput Bearing CageAvailable in KIT 2889Housing Cup bearingsAvailable in KIT 28892-3/8"-46T spline (no slinger)1/2" NPT x 9/16" 37 flare3.00" x 3.75" OD x .79" longPurchase separate from KIT 25407/16"-14 thd x 1.75".47" ID x .81" OD x .09" wide7/16"-1.5"7/16"-6.0"

MTC-4208X / XP ionDeclutch AssemblyBearing ConeBearing CupPTO ShaftShift ForkClutch CollarPush RodShifter PistonO-RingCover PlateCapscrewShifter SpringCapConnector Switch Assy - Disengage (Optional)Oil Seal AssemblyBearing SpacerBearing SpacerBearing SpacerBearing SpacerBearing SpacerBearing SpacerBearing SpacerBearing SpacerBearing SpacerBearing SpacerBearing SpacerBearing SpacerBearing 262.265.268.271.274.277.28".283"O-RingFlat WasherSpecial ScrewConnector Switch Assy - EngagePlugWasher1111186Part 22WA-34CommentsNot Shown

MTC-4208X / XP SERVICE KITSPart NamePart NumberQuantityDescriptionKIT 2894PTO Assy.Washer - FlatCapscrew - LongCapscrew - ShortDowel - PinPTO U-48575-X-12925-X-12915-X-132721222121KIT 2562Unitized Seal - Forward & Rear OutputMultiple-Lip Seal - Input ShaftO-Ring - Shift PistonO-Ring (Outer)Snap RingO-RingO-Ring (Housing)O-Ring - Input Bearing Cage7/16"-6.0"7/16"-1.5"Seal/Snap Ring Kit3.25" ID x 4.25" OD x .86" long3.25" ID x 4.25" OD x .58" long1.459" ID x .208" thick.734" ID x .139" thick.689" ID1.71" ID x .139" thick.984" ID x .139 thick7.483" x .139" thickKIT 2889Shim - .003"Shim - .005"Shim - .010"Shim - .010"Shim - .005"Shim - .003"Shim - .0197"Shim 3-Q-31112803-R-31122803-F-28665555555Input bearing 29-U-1503S2710A-24411112937111214188771228M45 x 1.5 thd.1.79" ID x 3.00" OD x .19" wide2.25"-12 thd.2.28" ID x 3.25" OD x .32" wideKIT 2890Lock NutWasherLock Nut - Rear Input ShaftWasher - HardenedCapscrew (Speed Sensor Retainer)Washer (Speed Sensor Retainer)CapscrewWasher - HardenedBolt/CapscrewBolt/CapscrewPlug - Oil RestrictionDowelDrain Plug - MagneticPlugFill PlugCapscrewWasher - FlatCapscrewWasher - HardenedMale ConnectorScrew - Special (Sensor Plug)WasherCapscrewHousing bearing cupsFastener Kit77/16"-14 thd x 1.75".47" ID x .81" OD x .09" Wide7/16" x 1.5"3/8" x 1.5".090" orifice.375" dia x 1.00" long3/4"-14 NPT square socket3/8"-18 NPT3/4"-14 NPTM8 x 1.25.34" ID x .62" OD x .06" wide1/2"-13 thd x 1.75".53" ID x .88" OD x .09" wide3/4"-14 NPT / 1 1/16"-12 FlareOptional M16 x 1-6g.97" ID x .81" OD x .09" wide

MTC-4208X / XP SERVICE KITSPart NamePart NumberQuantityKIT 2590Shaft - InputSnap RingPlug - Oil RestrictionInput Shaft Kit3297-H-15421229-P-48001250-M-1313111KIT 2891Collar - ClutchShift ForkFront Output Shift Fork/Collar 36911222121KIT 2895Shift CylinderPiston - ShiftPiston - Shift (Inner)O-Ring (Outer)O-Ring (Housing)O-RingO-Ring - Shift PistonPiston (Outer)DescriptionShift Cylinder Kit8.734" ID x .139" thick.984" ID x .139" thick1.17" ID x .139" thick

MTC-4208X / XP YOKESTransfer CaseModel NumbersMTC4208X 100 100 205MTC4208X 101 100 205Part NumbersFront Output140TYS38A140TYS38AFront Input17TYS38-7617TYS38-76Rear Output140TYS38A170TYS38-4ANote: Other yokes under RAP and RCE spline code (2-3/8"-46T) will fit the mainshafts. Yokes under RAI spline code (2"-39T) will fit the power take off unit. However,all yokes must be compatible with unitized seals.For more information about yoke type, spline size, or compatibility seehttp://xpresswayplus.arvinmeritor.com , http://www.meritorhvs.com/LODSearch.aspx,or call 1-866-ONTRAC1SEAL REPLACEMENTMeritor 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.Transfer Case ModelMTC-4208, -4210 and -4213MTC-4208 and -4210MTC-4213MTC-4213MTC-4208 and -4210Seal PositionInput ShaftForward and Rear OutputForward OutputRear OutputPTO SealSeal ServicePart vious SealPart A-1205P2590Seal Driver2728T1KIT 4454KIT 4454KIT 4454KIT 4454Sleeve Driver2728T2NANANANA

MERITOR AFTERMARKET PARTS WARRANTYWe warrant all new parts for one year from date of shipment to the buyer against defective material orworkmanship (but not against damage caused by accident, abuse or improper installation, maintenanceor repair) when such parts are used on vehicles the specifications of which have been approved by ourEngineering Department.As the exclusive remedy under this warranty, we will, at our option, repair or replace such parts free ofcharge, or take back the nonconforming parts and refund the monies paid by buyer for such parts, iffound on examination by us to be nonconforming and if any necessary return charges are prepaid.If it is necessary to return any parts under this warranty, buyer agrees not to make any deduction onaccount thereof from remittances on current accounts while claims are in the process of disposition.Any expense incurred without our consent for repairs or replacement will not be allowed.THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES OR CONDITIONS,EXPRESS, IMPLIED OR STATUTORY, INCLUDING ANY IMPLIED WARRANTY OFMERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE. IN NO EVENT SHALL SELLERBE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE.Only genuine Meritor replacement parts are covered by this aftermarket parts warranty.Information contained in this publication is ineffect at the time the publication was approvedfor printing and is subject to change withoutnotice or liability. Meritor Heavy Vehicle Systems,LLC, reserves the right to revise the informationpresented or discontinue the production of partsdescribed at any time.Meritor Heavy Vehicle Systems, LLC7975 Dixie HighwayFlorence, KY 41042 rvinmeritor.comIssued 4/2009PB-0910 2009 ArvinMeritor, Inc.

Maintenance Manual MM-0146, Transfer Cases, for more information. Transfer Case MTC4208X / XP. MTC4208 X / XP - Front. MTC4208 X / XP - Rear. MTC4208 X / XP - PTO. Item Description Qty Part No. Comments 1 Capscrew - Sensor Retainer 1 S-244-2 1a Washer - Sensor Retainer 1 WA-34