Meritor MTC Series User manual

Copyright Meritor, Inc., 2021
MM-2034 / Issued 02-21
Page 1Printed in USA
MTC-3206-FV (TC-237)
ONE-PIECE TRANSFER CASE
MT
C
S
eries
MAINTENANCE MANUAL MM-2034

Service Notes
About This Manual
This manual provides service and repair procedures for Meritor MTC-
3206-FV (TC-237) One-Piece Transfer Case.
How to Obtain Additional Maintenance
and Service Information
Visit Literature on Demand at meritor.com to access and order
additional information. Additional information is also available at
meritorbullpen.com.
Contact the OnTrac™ Customer Call Center at 866-668-7221
(United States and Canada); 001-800-889-1834 (Mexico); or
email [e-mail].
If Parts, Tools, and Supplies are Specified
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 [e-mail] 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. Meritor Heavy Vehicle Systems, LLC, reserves the
right to revise the information presented or to discontinue the produc-
tion of parts described at any time.

Copyright Meritor, Inc., 2021Printed in USA
MM-2034 / Issued 02-21
Page i
Contents
Table of Contents
About This Manual............................................... i
Section 1: Safety Information ............................. 1
Before You Begin Service Procedures ............................... 1
Hazard Alert Messages .................................................... 1
Section 2: Illustrations........................................ 2
Front View....................................................................... 2
Rear View ....................................................................... 2
Cross-Section View.......................................................... 3
Section 3: Introduction........................................ 4
Description ..................................................................... 4
Technical Specifications................................................... 4
Identification Tag ............................................................. 5
Model Nomenclature ....................................................... 5
Operation........................................................................ 6
Section 4: Removal............................................. 7
Hazard Alert Messages .................................................... 7
Removing the Transfer Case Assembly.............................. 7
Section 5: Disassembly....................................... 8
Hazard Alert Messages .................................................... 8
General Disassembly ....................................................... 8
Disassembly of Sub-assemblies ..................................... 18
Handling Removed Components..................................... 20
Section 6: Prepare Parts for Assembly ............. 21
Hazard Alert Messages .................................................. 21
Clean and Dry Parts....................................................... 21
Inspect Parts................................................................. 22
Section 7: Assembly ......................................... 26
Hazard Alert Messages .................................................. 26
Assembly Guidelines...................................................... 26
Input Shaft Assembly..................................................... 27
Intermediate Shaft Assembly.......................................... 29
Rear Output Shaft Assembly........................................... 30
Front Output Shaft Assembly.......................................... 31
General Assembly.......................................................... 33
Section 8: Installation ....................................... 46
Hazard Alert Messages .................................................. 46
Installing the Transfer Case Assembly ............................. 46
Section 9: Lubrication....................................... 47
Hazard Alert Messages .................................................. 47
Lubricant Capacity......................................................... 47
Oil Change Intervals ...................................................... 47
Checking the Air Pressure Circuit ................................... 47
Lubricant Type............................................................... 47
Checking Oil ................................................................. 48
Draining Oil................................................................... 48
Filling Oil....................................................................... 49
Operating Temperature .................................................. 49
Section 10: Torque Specifications..................... 50
Section 11: Vehicle Towing Instructions ........... 51
Section 12: Tools............................................... 52
Bearing Lock Nut Socket................................................ 53
Rear Output Seal Driver ................................................. 54
Rear Housing Bearing Cup Driver ................................... 55
Front Bearing Cup Driver................................................ 56
Front Output Bearing Cup Driver..................................... 57
End Play Setup Tool ....................................................... 58

Copyright Meritor, Inc., 2021
MM-2034 / Issued 02-21
Page 1 Printed in USA
1Safety Information
Safety Information
Before You Begin Service Procedures
1. Read and understand all instructions and procedures before you
begin to service components.
2. Read and observe all hazard alert messages in this publication.
They provide information that can help prevent serious personal
injury, damage to components, or both.
3. Follow your company’s maintenance and service, installation, and
diagnostics guidelines.
4. Use special tools when required to help avoid serious personal
injury and damage to components.
Hazard Alert Messages
Read and observe all hazard alert messages in this publication. They
provide information that can help prevent serious personal injury,
damage to components, or both.
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.

Copyright Meritor, Inc., 2021
Printed in USA
MM-2034 / Issued 02-21
Page 2
2Illustrations
Illustrations
Front View
Breather
Output to
Front
Input
Front Drive
Engagement
Indicator Switch
Clutch Cylinder
4018188a
Rear View
Rear Output
Shift Cylinder
4018189a