Meritor T-2111 Series User manual

Meritor MTC3111 (T-2111) Series Transfer Case Service
Manual
Pro Gear Meritor MTC3111 (T-2111) Transfer Case Parts Manual to assist in identifying your
Meritor / Fabco unit.
If you need any assistance identifying the correct transfer case unit for your truck and
equipment, contact your Meritor / Fabco replacement part specialists at Pro Gear and
Transmission.
Pro Gear Transmission has same day shipping and 1000’s of products in stock and ready to ship
internationally for your next project.
For parts or service contact the Meritor / Fabco specialists at Pro Gear & Transmission, Inc.
1 [phone]
(407)872-1901
[email protected]
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Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

T-2111 Series
Transfer Cases
Maintenance Manual No. 3D
Revised 2-96
T-2111-D T-2111-SD
T-2111-PD T-2111-SPD
T-2111-T T-2111-ST
T-2111-HP T-2111-SHP
~MERITOR
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

SERVICE NOTES
This Maintenance Manual describes the correct service and repair procedures for the Rockwell T-2111 Series
Transfer Case. The information contained in this manual was current at the time of printing and is subject to
change without notice or liability.
You must follow your company safety procedures when you service or repair equipment. Be sure you under-
stand all the procedures and instructions before you begin work on the unit.
Rockwell uses the following types of notes to give warning of possible safety problems and to give information
that will prevent damage to equipment.
WARNING
A warning indicates procedures that must be followed exactly. Serious personal injury can occur if the
procedure is not followed.
CAUTION
A caution indicates procedures that must be followed exactly. If the procedure is not followed, damage
to equipment or components can occur. Serious personal injury can also occur in addition to damaged
or malfunctioning equipment or components.
TORQUE
This symbol is used to indicate fasteners that must be tightened to a specific torque value.
NOTE:
A note indicates an operation, procedure or instruction that is important for correct services.
Some procedures require the use of special tools for safe and correct service. Failure to use these special
tools when required, can cause serious personal injury to service personnel or damage to vehicle components.
T
!
!
ASBESTOS AND NON-ASBESTOS FIBER WARNING
Current Rockwell DCM brake linings do not use asbestos fibers. Some aftermarket brake linings contain
asbestos fiber, a cancer and lung disease hazard. Some brake linings contain non-asbestos fibers whose
long term effects are unknown.
Caution should be exercised in handling both asbestos and non-asbestos materials as described on page 2.
!
•
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

T-2
NOTE: Parts sho
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188187186185
184
183
182
181
180
179
178
177
176
189
175
175B
175A
173
174
172
171
190
191
192
193
194
195
196
197
198
199
200
218
217
216
213
214
215
92
93
91
89
90
88
85
84
87
86
212
211
208
210
209
209A
201
202
203
204
205
206
207
139
140
141
142
142A
143
144
145
146
138
137
82
83
81
79
80
78
97
96
95
94
98
99
102
101
100
136
147148149150
151
152
153
154
155
156
156A
157A
157
164
165
166
167
168
169
170
158
159
160
161
162
163
147148149150
151
152
153
154
155
156
157
164
165
166
167
168
169
170
158
159
160
161
162
163
77
76
75
74
73
129
130
131
132
133
134
135
103
105
104
72C
DECLUTCH
P.T.O. DECLUTCH
OIL PUMP
A
SE
72B
72A
71
70
69
72
106
107
126
127
128
125
MAIN C
A
PROPORTIONAL
DIFFERENTIAL
DCM BRAKE
121 122119 120 124 123
108
109
111
110
108A
108B
108D
108C
115A
116
117
118
113112 114
114A
115
68
67
66
65
64
63
62
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60
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Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

T-2111 SERIES DCM BRAKES
1 Locknut-brake 1
2 Washer-brake 1
3 Nut-brake drum to flange 8
4 Spacer-brake drum to flange 8
5 Flange/Yoke-brake drum 1
6 Drum-brake 1
7 Lockwire-brake drum to hub capscrew 2
8 Bolt-brake drum to hub 8
9 Spacer-brake hub 1
10 Spring-brake shoe return 4
11 Brake Shoe and Lining Assy. 2
12 Lining-brake 2
13 Rivet-Lining to shoe 28
14 Strut Assy. 1
15 Camshaft 1
16 Backing Plate Assy. 1
17 Capscrew-cover adapter to cage 4
18 Washer-cover adapter to cage 4
19 Lever-brake 1
20 Washer-brake 1
21 Nut-lock 1
22 Deflector-brake adapter 1
23 Dust Shield 1
24 Oil Seal-brake bearing cage 1
25 Oil Seal-brake bearing cage 1
26 Cage Assy.-brake bearing 1
27 Capscrew-brake bearing cage 4
28 Washer-brake bearing cage capscrew 4
T-2111 SERIES PROPORTIONAL DIFFERENTIAL
29 Adapter-brake assy. 1
30 Cone-proportional diff. cage shaft 1
31 Cup-proportional diff. cage shaft 1
32 Capscrew-diff. cage to gear case cover 12
33 Washer-diff. cage to gear case cover 12
34 Cage-proportional diff. 1
35 Plug-oil drain 1
36 Shim-proportional diff. cage bearing 2
spacer
37 Cup-proportional diff. cage shaft 1
38 Cone-proportional diff. cage shaft 1
39 Shaft-output outer 1
40 Gear-proportional diff. ring 1
41 Snap Ring-planet, pinion shaft 3
42 Washer-planet. pinion thrust 3
43 Pinion Planet Spider 3
44 Shaft-planet pinion 3
45 Spider Assy.-planet gear 1
46 Setscrew-planet pinion shaft 3
47 Snap Ring-outer output shaft 1
48 Gear-planet sun 1
49 Snap Ring-inner output shaft 1
50 Capscrew-output shaft cage 8
51 Washer-output shaft cage capscrew 8
52 Spacer-output shaft planet spider 1
53 Cover-proportional diff. gear case 1
54 Plug-oil fill hole 1
T-2111 SERIES MAIN CASE
55 Nut-input shaft lock 1
56 Washer-input shaft 1
57 Flange/Yoke-input shaft 1
58 Deflector-input shaft 1
59 Oil Seal-input shaft bearing cage 1
60 Oil Seal-input shaft bearing cage 1
61 Capscrew-input shaft bearing cage 8
62 Washer-bearing cage capscrew 8
63 Cage Assy.-input shaft bearing 1
64 Plug-transfer case 1
65 Plug-transfer case 1
66 Case-transfer 1
67 Plug-transfer case 1
68 Dowel-transfer case 2
69 Cup-input shaft bearing 1
70 Cone-input shaft bearing 1
71 Shaft-input 1
72 Shaft-input 1
72A Shaft-input 1
72B Retaining Plate-bearing 1
72C Capscrew-retaining plate 2
73 Bushing-input 1
74 Gear-input shaft 1
75 Spacer-input shaft 1
76 Cone-input shaft bearing 1
77 Cup-input shaft bearing 1
78 Plug-transfer case 1
79 Case-transfer 1
80 Plug-transfer case 1
81 Elbow-oil breather 1
82 Breather-transfer case 1
83 Shim-input shaft 3
84 Spacer-input shaft 1
85 Cage Assy.-input shaft bearing 1
86 Washer-bearing cage capscrew 8
87 Capscrew-input shaft bearing cage 8
88 Oil Seal-input shaft bearing cage 1
89 Oil Seal-input shaft bearing cage 1
90 Deflector-input flange/yoke 1
91 Flange/Yoke-input shaft 1
92 Washer-input shaft 1
93 Nut-input shaft 1
94 Capscrew-idler gear bearing cage 8
95 Washer-bearing cage capscrew 8
96 Cage Assy.-idler gear bearing 1
97 Shim-idler gear 3
98 Plug-oil suction 1
99 Plug-transfer case 1
100 Plug-oil fill 1
101 Locknut-transfer case capscrew 20
102 Washer-transfer case capscrew 20
103 Cup-idler gear bearing 1
104 Cone-idler gear bearing 1
105 Gear-idler 1
106 Cone-idler gear bearing 1
107 Cup-idler gear bearing 1
108 Plug-oil fill 1
108A Cap-filler pipe 1
108B Nipple-filler pipe 1
108C Elbow-filler pipe 1
108D Nipple-filler pipe 1
109 Cage Assy.-idler gear bearing 1
110 Washer-bearing cage capscrew 8
111 Capscrew-idler gear bearing cage 8
112 Nut-output shaft 1
113 Washer-output shaft 1
114 Flange/Yoke-output shaft 1
114A Deflector-output shaft 1
115 Oil Seal-output shaft 1
115A Oil Seal-output shaft bearing cage 1
116 Capscrew-output shaft bearing cage 4
117 Washer-bearing cage capscrew 4
118 Cage Assy.-output shaft bearing 1
119 Screw-name plate 2
120 Name Plate 1
121 Capscrew-transfer case 20
122 Washer-transfer case capscrew 20
123 Plug-oil drain 1
124 Plug-oil suction 1
125 Plug-transfer case 1
126 Cup-output shaft bearing 1
127 Cone-output shaft bearing 1
128 Spacer-output shaft bearing to gear 1
129 Shaft-output —
130 Shaft-output 1
131 Bushing-output 1
132 Gear-output shaft 1
133 Cone-output shaft bearing 1
134 Cup-output shaft bearing 1
135 Collar-clutch 1
136 Plug-oil drain 1
137 Shim-output shaft 3
138 Spacer-output shaft 1
139 Cage Assy.-output shaft bearing 1
140 Washer-bearing cage capscrew 8
141 Capscrew-output shaft bearing cage 8
142 Oil Seal-output shaft 1
142A Oil Seal-output shaft bearing cage 1
143 Deflector-output flange/yoke 1
144 Flange/Yoke-output shaft 1
145 Washer-output shaft 1
146 Nut-output shaft 1
T-2111 SERIES 5450 LB-FT DECLUTCH/P.T.O.
147 Nut-declutch shaft 1
148 Washer-declutch shaft 1
149 Flange/Yoke-declutch 1
150 Deflector-output flange/yoke 1
151 Capscrew-declutch shift cover 4
152 Washer-shift cover capscrew 4
153 Cover-declutch cage 1
154 Quad Ring-declutch piston 1
155 Piston-declutch 1
156 Spring-declutch piston return 1
156A Washer-cage capscrew 1
157 Fork-declutch 1
157A Nipple 1
158 Setscrew-declutch fork 1
159 Washer-declutch plate capscrew 4
160 Capscrew-declutch plate 4
161 Switch Assy.-declutch shift 1
162 Plate-declutch 1
163 Shaft-declutch 1
164 Cage-declutch bearing 1
165 Washer-declutch cage capscrew 8
166 Capscrew-declutch bearing cage 8
167 Bearing-declutch shaft ball 1
168 Snap Ring-declutch bearing 1
169 Oil Seal Assy.-declutch cage 1
170 Oil Seal Assy.-declutch cage 1
T-2111 SERIES 11,000 LB-FT DECLUTCH/P.T.O.
171 Shaft-declutch 2
172 Collar-clutch 2
173 Needle Bearing-declutch shaft 2
174 Shaft Assy.-declutch 2
175 Switch Assy.-declutch shift 2
175A Washer-declutch plate 1
175B Plug-declutch plate 1
176 Capscrew-declutch plate 8
177 Washer-declutch plate capscrew 8
178 Plate-declutch 2
179 Setscrew-declutch fork 2
180 Fork-declutch 2
181 Plug-declutch cage 2
182 Quad Ring-declutch piston 2
183 Piston-declutch 2
184 Quad Ring-declutch piston 2
185 Spring-declutch piston return 2
186 Cover-declutch cage 2
187 Washer-shift cover capscrew 8
188 Capscrew-declutch shift cover 8
189 Switch Assy.-declutch shift 2
190 Cage-declutch bearing 2
191 Washer-declutch cage capscrew 16
192 Capscrew-declutch brg. cage 16
193 Bearing-declutch shaft ball 2
194 Snap Ring-declutch bearing 2
195 Oil Seal Assy.-declutch cage 2
196 Oil Seal Assy.-declutch cage 2
197 Deflector-declutch yoke 2
198 Flange/Yoke-declutch 1
199 Washer-declutch shaft 2
200 Nut-declutch shaft 2
T-2111 SERIES OIL PUMP
201 Fitting/Filter Assy. 1
202 Fitting-inlet tube to filter 1
203 Button-pump drive 1
204 Coupling-oil pump 1
205 Pump Assy-oil 1
206 Washer-oil pump to cage capscrew 4
207 Capscrew-oil pump to idler cage 4
208 Fitting-oil pump Assy. 1
209 Tube Assy.-lube outlet 1
209A Clamp 2
210 Fitting-outlet tube to cage 1
211 Fitting-oil pump Assy. 1
212 Tube Assy.-lube inlet 1
213 Cage-bearing transfer case 1
214 Washer-cage capscrew 1
215 Capscrew 1
216 Cage-bearing transfer case 1
217 Washer-cage capscrew 1
218 Capscrew-output bearing shaft 4
Item Description Qty Item Description Qty Item Description Qty
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

Table of Contents
Page 1
SUBJECT PAGE
Asbestos and Non-Asbestos Fiber Warnings....................................................................................2
1. Introduction
Description..........................................................................................................................................................3
Operation............................................................................................................................................................5
Identification........................................................................................................................................................6
2. Removal and Installation
Remove Transfer Case from Vehicle .................................................................................................................7
Install Transfer Case in Vehicle .........................................................................................................................8
Drain and Replace Oil.........................................................................................................................................8
Check and Adjust Oil Level ................................................................................................................................8
3. Disassembly
Disassemble Parking Brake................................................................................................................................9
Disassemble Proportional Differential...............................................................................................................10
Disassemble Planetary Spider Assembly.........................................................................................................10
Disassemble Yokes from Input and Output Shafts...........................................................................................11
Disassemble Bearing Cages from Front Half Side...........................................................................................11
Disassemble Declutch Assembly......................................................................................................................12
Disassemble Proportional Differential Lockout and
Front Output Shaft Assembly .......................................................................................................................13
Disassemble Housing Valves...........................................................................................................................13
Disassemble Bearing Cages and Differential Cover from Housing .................................................................14
Disassemble Idler Gear, Input and Output Shaft Assemblies ..........................................................................14
Disassemble Input and Idler Shaft Bearing Cages ..........................................................................................14
4. Cleaning and Inspection
Clean Ground and Polished Parts....................................................................................................................15
Clean Rough Parts ...........................................................................................................................................15
Clean Transfer Case Assemblies.....................................................................................................................15
Dry Cleaned Parts ............................................................................................................................................15
Prevent Corrosion and Rust on Cleaned Parts.................................................................................................15
Inspect Parts.....................................................................................................................................................16
5. Assembly
Assemble Input Shaft, Idler Gear and Output Shaft Assemblies......................................................................18
Assemble Bearing Cages and Differential Cover in Rear Case Half................................................................19
Install Input Shaft, Idler Gear and Output Shaft Assemblies ............................................................................19
Assemble Transfer Case Housing....................................................................................................................20
Install Remaining Bearing Cages .....................................................................................................................20
Check Bearing Endplay....................................................................................................................................22
Assemble Front Output Shaft Differential Lockout Assembly...........................................................................23
Install Yokes .....................................................................................................................................................24
Assemble Planetary Spider Assembly..............................................................................................................24
Assemble Proportional Differential ...................................................................................................................25
Check Bearing Endplay....................................................................................................................................25
!
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

Table of Contents (continued)
SUBJECT PAGE
Install Output Shaft and Bearing Cage Assembly ............................................................................................27
Assemble Parking Brake ..................................................................................................................................27
Application of Silicone Gasket Material ............................................................................................................29
6. Lubrication
Recommended Oil............................................................................................................................................30
Oil Substitutes...................................................................................................................................................30
Acceptable Motor Oil Alternatives.....................................................................................................................30
Transfer Case Oil Levels..................................................................................................................................31
7. Diagnostics
Overheating......................................................................................................................................................32
Oil Blowing Out Of Breather .............................................................................................................................32
Oil Seal Leaks...................................................................................................................................................32
Noise/Vibration .................................................................................................................................................32
Declutch Indicator Not Functioning...................................................................................................................32
Premature Gear/Bearing Wear.........................................................................................................................32
8. Specifications
T-2111-D/SD, T-2111-PD/SPD, T-2111-T/ST, T-2111-HP/SHP Specifications...............................................33
Allowable Maximum Speed ..............................................................................................................................33
Transfer Case Oil Change Intervals .................................................................................................................34
Transfer Case Oil Specifications ......................................................................................................................34
Transfer Case Oil Capacities............................................................................................................................34
Driveline Application Guideline.........................................................................................................................35
Driveline Length Guideline................................................................................................................................35
Maximum Driveline Angle Guideline.................................................................................................................35
Torque Chart.....................................................................................................................................................36
Tire Mismatch...................................................................................................................................................37
T-2111 Transfer Case Variations......................................................................................................................38
Page 1A
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

NON-ASBESTOS
FIBER WARNING
The following procedures for servicing brakes are recommended
to reduce exposure to non-asbestos fiber dust, a potential cancer
and lung disease hazard. Material Safety Data Sheets are available
from Rockwell.
Hazard Summary
Most recently manufactured brake linings do not contain asbestos fibers. These brake linings
may contain one or more of a variety of ingredients, including glass fibers, mineral wool,
aramid fibers, ceramic fibers and silica that can present health risks if inhaled. Scientists
disagree on the extent of the risks from exposure to these substances. Nonetheless,
exposure to silica dust can cause silicosis, a non-cancerous lung disease. Silicosis gradually
reduces lung capacity and efficiency and can result in serious breathing difficulty. Some
medical experts believe other types of non-asbestos fibers, when inhaled, can cause similar
diseases of the lung. In addition, silica dust and ceramic fiber dust are known to the State of
California to cause lung cancer. U.S. and international agencies have also determined that
dust from mineral wool, ceramic fibers and silica are potential causes of cancer.
Accordingly, workers must use caution to avoid creating and breathing dust when servicing
brakes. Specific recommended work practices for reducing exposure to non-asbestos dust
follow. Consult your employer for more details.
Recommended Work Practices
1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from
other operations to reduce risks to unprotected persons.
2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for silica of
0.1 mg/m3as an
8-hour time-weighted average. Some manufacturers of non-asbestos brake linings
recommend that exposures to other ingredients found in non-asbestos brake linings be kept
below 1.0 f/cc as an 8-hour time-weighted average. Scientists disagree, however, to what
extent adherence to these maximum allowable exposure levels will eliminate the risk of
disease that can result from inhaling non-asbestos dust.
Therefore, wear respiratory protection at all times during brake servicing, beginning with the
removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA) filter
approved by NIOSH or MSHA, if the exposures levels may exceed OSHA or manufacturer’s
recommended maximum levels. Even when exposures are expected to be within the
maximum allowable levels, wearing such a respirator at all times during brake servicing will
help minimize exposure.
3. Procedures for Servicing Brakes.
a) Enclose the brake assembly within a negative pressure enclosure. The enclosure should
be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place,
use the HEPA vacuum to loosen and vacuum residue from the brake parts.
b) As an alternative procedure, use a catch basin with water and a biodegradable, non-
phosphate, water-based detergent to wash the brake drum or rotor and other brake parts.
The solution should be applied with low pressure to prevent dust from becoming airborne.
Allow the solution to flow between the brake drum and the brake support or the brake rotor
and caliper. The wheel hub and brake assembly components should be thoroughly wetted
to suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts
clean with a cloth.
c) If an enclosed vacuum system or brake washing equipment is not available, carefully clean
the brake parts in the open air. Wet the parts with a solution applied with a pump-spray
bottle that creates a fine mist. Use a solution containing water, and, if available, a
biodegradable, non-phosphate, water-based detergent. The wheel hub and brake
assembly components should be thoroughly wetted to suppress dust before the brake
shoes or brake pads are removed. Wipe the brake parts clean with a cloth.
d) Wear a respirator equipped with a HEPA filter approved by NIOSH of MSHA when
grinding or machining brake linings. In addition, do such work in an area with a local
exhaust ventilation system equipped with a HEPA filter.
e) NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a
HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents,
flammable solvents, or solvents that can damage brake components as wetting agents.
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by
wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you
empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter
approved by NIOSH or MSHA, if the exposure levels may exceed OSHA or manufacturers’
recommended maximum levels. When you replace a HEPA filter, wet the filter with a fine mist
of water and dispose of the used filter with care.
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or
smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a
HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not
shake or use compressed air to remove dust from work clothes.
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with
care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on
waste disposal.
Regulatory Guidance
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United
States, are made to provide further guidance to employers and workers employed within the
United States. Employers and workers employed outside of the United States should consult
the regulations that apply to them for further guidance.
!
ASBESTOS FIBER WARNING
The following procedures for servicing brakes are recommended
to reduce exposure to asbestos fiber dust, a cancer and lung
disease hazard. Material Safety Data Sheets are available from
Rockwell.
Hazard Summary
Because some brake linings contain asbestos, workers who service brakes must understand the
potential hazards of asbestos and precautions for reducing risks. Exposure to airborne asbestos
dust can cause serious and possibly fatal diseases, including asbestosis (a chronic lung disease)
and cancer, principally lung cancer and mesothelioma (a cancer
of the lining of the chest or abdominal cavities). Some studies show that the risk of lung cancer
among persons who smoke and who are exposed to asbestos is much greater than the
risk for non-smokers. Symptoms of these diseases may not become apparent for 15, 20 or more
years after the first exposure to asbestos.
Accordingly, workers must use caution to avoid creating and breathing dust when servicing
brakes. Specific recommended work practices for reducing exposure to asbestos dust follow.
Consult your employer for more details.
Recommended Work Practices
1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from
other operations to reduce risks to unprotected persons. OSHA has set a maximum allowable
level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average and 1.0 f/cc
averaged over a 30-minute period. Scientists disagree, however, to what extent adherence to the
maximum allowable exposure levels will eliminate the risk of disease that can result from inhaling
asbestos dust. OSHA requires that the following sign be posted at the entrance to areas where
exposures exceed either of the maximum allowable levels:
DANGER: ASBESTOS
CANCER AND LUNG DISEASE HAZARD
AUTHORIZED PERSONNEL ONLY
RESPIRATORS AND PROTECTIVE CLOTHING
ARE REQUIRED IN THIS AREA
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter
approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes,
beginning with the removal of the wheels.
3. Procedures for Servicing Brakes.
a) Enclose the brake assembly within a negative pressure enclosure. The enclosure should be
equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use
the HEPA vacuum to loosen and vacuum residue from the brake parts.
b) As an alternative procedure, use a catch basin with water
and a biodegradable, non-phosphate, water-based detergent to wash the brake drum or
rotor and other brake parts. The solution should be applied with low pressure to prevent dust
from becoming airborne. Allow the solution to flow between the brake drum and the brake
support or the brake rotor and caliper. The wheel hub and brake assembly components
should be thoroughly wetted to suppress dust before the brake shoes or brake pads are
removed. Wipe the brake parts clean with a cloth.
c) If an enclosed vacuum system or brake washing equipment is not available, employers may
adopt their own written procedures for servicing brakes, provided that the exposure levels
associated with the employer’s procedures do not exceed the levels associated with the
enclosed vacuum system or brake washing equipment. Consult OSHA regulations for more
details.
d) Wear a respirator equipped with a HEPA filter approved
by NIOSH or MSHA for use with asbestos when grinding or machining brake linings. In
addition, do such work in an area with a local exhaust ventilation system equipped with a
HEPA filter.
e) NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA
filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents,
flammable solvents, or solvents that can damage brake components as wetting agents.
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet
wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty
vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved
by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter, wet the filter with a
fine mist of water and dispose of the used filter with care.
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke.
Shower after work. Do not wear work clothes home. Use a vacuum equipped with a HEPA filter
to vacuum work clothes after they are worn. Launder them separately. Do not shake or use
compressed air to remove dust from work clothes.
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care,
such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste
disposal.
Regulatory Guidance
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United
States, are made to provide further guidance to employers and workers employed within the
United States. Employers and workers employed outside of the United States should consult the
regulations that apply to them for further guidance.
!
Page 2
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

Page 3
Section 1
Introduction
Description
The Rockwell T-2111-D, T-2111-PD, T-2111-T,
T-2111-HP and T-2111-SD/SPD/ST transfer cases
are a three-shaft design with single speed front and
rear output and 1:1 ratio for use with 4x4 and 6x6
vehicles. Their 16.125 inch (409.5 mm) input to
output drop permits engine clearance. Figure 1.
NOTE:
The T-2111-SD/ST/SPD transfer cases vary only in
their main case configuration from the T-2111. All
options and features are the same as described in
this Maintenance Manual.
Rockwell transfer case air actuated Front Axle
Declutch, Proportional Differential (PD) and Full
Torque PTO Lockups options are driver controlled
from the cab. By activating an air plunger or electric
switch usually mounted on the instrument panel, the
driver engages or disengages a mechanical clutch in
each of these devices. Optional indicator switches
show when each clutch is fully engaged or
disengaged.
Figure 1
Air actuated options include:
•Axle declutch option permits shifting from
4-wheel drive to 2-wheel drive. Figure 2.
Figure 2
OPTIONAL AXLE DECLUTCH
5450 lb-ft (7400 N•m)
TYPICAL 4x4 HOOKUP
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Section 1
Introduction
Page 4
•Proportional Differential with a 30/70 torque split
(Front axle, 30%; rear axle, 70%) can be locked up
to give full power to each axle. Figure 5.
Other options include:
•Indicator switches for Declutches, Full Torque
PTOs and Proportional Differentials.
•A 12" x 3" (305 mm x 76 mm) DCM parking
brake on the rear output shaft.
•Oil pump to provide lubrication to top mounted
PTOs, declutches or main case assembly in 500
rpm duty cycle operations.
•SAE 2-bolt hydraulic pump mount.
•Thru-shaft for higher torque applications.
•Multiple PTOs and declutches to permit flexible
configurations. PTOs and declutches are available
in 5450 lb.-ft. (7400 N•m) and 11,000 lb.-ft.
(14900 N•m) capacities.
CAUTION
Continuous use of the axle declutch and
proportional differential on good operating
surfaces will damage the transfer case.
!
•PD option transfer cases permit full-time All-wheel
drive. Figure 3.
•Full torque PTO provides an outlet from the
transfer case to drive auxiliary power devices. PTO
has the same type of clutch as the declutch and PD
lockup units. Figure 4.
Figure 4
Figure 5
Figure 3
T-2111-PD TYPICAL CONFIGURATION
INPUT SHAFT WITH
OPTIONAL FULL TORQUE PTO / DECLUTCH
11,000 lb-ft (14900 N•m)
PROPORTIONAL
DIFFERENTIAL
OPTIONAL PROPORTIONAL
DIFFERENTIAL SHOWN WITH
OPTIONAL DCM PARKING BRAKE
12” x 3” DCM
BRAKE
(OPTIONAL)
PROPORTIONAL
DIFFERENTIAL
(OPTIONAL)
PROPORTIONAL
DIFFERENTIAL
(LOCKOUT)
INPUT
SHAFT
BRAKE
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

CAUTION
•
The declutch and PD lockup should only be
locked under poor operating conditions.
Turning radius and steering responsiveness
will be different in the locked condition. Under
poor operating conditions unlock the declutch
and PD lockup whenever possible.
•
Do not engage the declutch or PD lockup when
wheels are slipping or while the vehicle is
traveling up or down steep grades. Engaging
the declutch or PD lockup during these
conditions can cause damage to the transfer
case and a potential loss of vehicle stability.
4. Always monitor the optional engaged/disengaged
indicator lights. Do not operate the vehicle until the
proper engagement position is achieved.
Engaging and Disengaging the
Full Torque PTO
1. The PTO can be engaged or disengaged only
when:
•transmission in NEUTRAL
•vehicle stopped
•all transfer case prop shafts no longer turning
2. If engagement is initiated and the clutch does not
fully engage, put the transmission into LOW and
slowly begin to spin the transfer case until
engagement occurs. The operator will know
engagement occurs by:
•hearing engagement or disengagement
•improved vehicle performance
•optional indicator lights mounted in cab signal
engagement or disengagement.
3. When possible, the driven auxiliary device should
provide some resistance to spinning to assist in
engaging the PTO.
CAUTION
Do not engage the PTO if the transfer case is
stopped while the device that the PTO is to
drive is turning. Engaging the device during
these conditions can cause damage to the
transfer case.
4. Always monitor the optional engaged/disengaged
indicator lights. Do not operate the vehicle until the
proper engagement position is achieved.
Section 1
Introduction
Page 5
Operation
NOTE:
•
The Axle Declutch and Proportional Differential
(PD) Lockup provide maximum vehicle traction
on poor operating surfaces. Both provide
assured torque to all connected axles by
completely locking their input shafts together
to prevent spinout.
•
Disengage the Front Axle Declutch during normal
operation. Engage it only to provide additional
vehicle traction during poor operating conditions.
CAUTION
To avoid speed differences between axles, do not
actuate the declutch or PD lockup units during
normal driving conditions or high speed
operations.
Engaging the Front Axle Declutch and
PD Lockup
1. The declutch or PD lockup can be engaged only
when:
•vehicle stopped
•or vehicle operating at constant low speed
CAUTION
The wheels must not be slipping at the time
of engagement. This can cause damage to
components.
2. If engagement is initiated and the clutch does not
engage, turn the steering wheel in one direction
and rock the vehicle back and forth until
engagement occurs. The operator will know
engagement occurs by:
•hearing engagement
•improved vehicle performance
•optional indicator lights mounted in cab signal
engagement.
3. When the declutch or PD lockup are engaged, the
vehicle should be operated only at speeds under
25 mph (40 km).
!
!
!
!
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

Section 1
Introduction
Page 6
Identification T-2111 TRANSFER CASE
T - 2 1 1 1 - T 1 0 1 - 1 0 0
T-2111 LUBE PUMP
L P - 2 1 1 1 A - 1
T-2111 DECLUTCH/PTO/LOCKUP
P - 2 1 1 1 A - 1
Rockwell transfer case.
Number of speeds in transfer case.
Basic transfer case rating in
thousands of ft.. lbs.
Lube pump.
Lube pump designed for T-2111
transfer case.
Note: Lube pump required when
top shaft PTO provided.
PTO
Group of BOMs originally designed
for the T-2111 transfer case.
Bill of material (BOM) sequence
number. The first BOM in the series
is not given a number designation.
Pump group for use with 5,450 ft. lb.
(7400 N•m) PTO only. Absence of
“A” designation indicates use on
11,000 ft. lb. (14900 N•m) PTO.
LP-2111-1 on top of case.
Bill of material (BOM) sequence
number. The first BOM in the series
is not given a number designation.
Assembly designed with 5,450 ft. lb.
(7400 N•m). rated components.
Absence of “A” designation
indicates use of 11,000 lb.-ft.
(14900 N•m) components. Other
alphanumeric characters denote
configuration options.
* If a transfer case contains a combination of options, use the first
designation that the transfer case matches from the following given order:
- PLAIN IN/OUT TRANSFER CASE (No ID letter designation)
PD - PROPORTIONAL DIFFERENTIAL
HP - HYDRAULIC PUMP
T - THRU SHAFT
HC - HIGH CAPACITY DECLUTCH (20,000 lb.-ft./ 27116 N•m)
D - DECLUTCH/PTO UNIT
1.00:1 ratio. (standard)
Specification sequence number
associated with Bill of Material
T: Thru shaft configuration*
D: Declutch/PTO units
PD: Proportional differential units
HP: Hydraulic pump mount
SD: Short drop
SPD:Short, proportional differential
HC: High capacity declutch
(200,000 lb.-ft./ 27100 N•m)
When T-case used as
“Tower PTO.”
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

Section 2
Removal and Installation
Page 7
Remove Transfer Case from
Vehicle
WARNING
To prevent serious eye injury, always wear safe eye
protection when doing maintenance or service.
WARNING
The proportional differential eliminates dead engine
holding ability if one end of the vehicle
is raised without air pressure applied to the
differential lockout. Serious personal injury can
occur.
WARNING
Support the vehicle with safety stands. Do not
work under a vehicle only supported by jacks.
Jacks can slip or fall over and cause serious
personal injury.
1. Make sure the vehicle is on a level surface.
2. Put blocks under the wheels not being raised to
keep the vehicle from moving.
3. Raise the vehicle so that the area to be serviced
is off the ground. Support the vehicle with safety
stands.
4. Remove the drain plug from the bottom of the
transfer case and the Proportional Differential
(if equipped). Drain the lubricant from the transfer
case. See page 8.
Also remove the drain plug from the bottom of the
differential, if used, to drain the oil from the
differential. See page 8.
5. Disconnect the drivelines from the input and output
yokes or flanges of the transfer case.
6. Disconnect the brake actuator linkage from the
parking brake.
7. Disconnect the air line to the differential lockout or
the declutch/PTO.
8. Disconnect the harness for the indicator switch wires.
9. Use a hydraulic roller jack to support the transfer
case. Remove the mounting bolts that hold the case
to the vehicle.
10. Carefully remove the transfer case with the
hydraulic jack.
11. Steam clean the outside of the transfer case to
remove heavy amounts of dirt.
NOTE:
Close or cover all openings before steam cleaning.
These openings include the breather and oil/level
drain.
12. Attach angle iron brackets with bolts in the
mounting holes of the brake half of the transfer
case housing. Figure 6.
13. For a transfer case without lifting loops, install
eyebolts in the mounting holes in the other half of
the transfer case housing. The eye bolts permit
easier lifting of the transfer case.
WARNING
To avoid serious personal injury and possible
damage to components, be very careful when
using lifting devices.
•
Inspect to make sure that the lifting loops or
lifting straps are not damaged.
•
Always use both lifting loops and lifting straps
when lifting.
•
Do not subject lifting loops or lifting straps to
any shock or drop loading.
14. Use a lifting device attached to the lifting loops or
eye bolts to lift the transfer case. Use the angle iron
brackets to mount the case in the repair stand.
Figure 6.
!
!
!
!
EYEBOLT
ANGLE IRON
BRACKET
LIFTING
LOOP
Figure 6 EYEBOLT
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

Page 8
Install Transfer Case in Vehicle
1. With a lifting device, remove the transfer case from
the repair stand to a hydraulic roller jack. If used,
remove the temporary eyebolts and angle iron
brackets from the transfer case housing.
2. Move the transfer case into position under the
vehicle with the hydraulic roller jack.
3. Install the transfer case into the vehicle with the
mounting bolts. Tighten the bolts to the torque
specification supplied by the vehicle manufacturer.
4. Connect the drivelines to the input and output yokes
of the transfer case.
5. Connect the brake actuator linkage to the parking
brake.
6. Fill the transfer case with proper quantity of specified
lubricant. See page 34 for lubricant specifications
and capacities.
NOTE:
Allow time for the lubricant to flow through the rear
output bearing into the proportional differential if
the unit is so equipped.
Drain and Replace Oil
1. Make sure the vehicle is parked on a level surface.
Put a large container under the transfer case.
WARNING
•
Use only the type of lubricant specified by the
equipment manufacturer. Do not mix different
types of lubricant. The wrong lubricant can
cause damage, incorrect operation and serious
personal injury.
•
Do not reuse lubricant. Used lubricant can be
contaminated and can cause damage, incorrect
operation and serious personal injury.
2. Remove the drain plug from the bottom of the
transfer case. Drain and properly discard the oil.
Clean the plug. Figure 7.
3. Install and tighten the drain plug to 35-50 lb-ft
(47-68 N•m).
4. Clean the area around the fill plug. Remove the fill
plug from the transfer case.
5. Add the specified oil until the oil level is even with
the bottom of the fill plug hole or to top of standpipe
if used.
6. Install and tighten the fill plug to 35-50 lb-ft
(47-68 N•m).
Check and Adjust Oil Level
1. Make sure the vehicle is parked on a level surface.
2. Clean the area around the fill plug. Remove the fill
plug from the transfer case. Figure 7.
3. The oil level must be even with the bottom of the
hole for the fill plug or to top of standpipe if used.
See page 31.
•If oil flows from the hole when the plug is loosened,
the oil level is high. Let the oil drain to the correct
level.
•If the oil level is below the bottom of the hole of the fill
plug, add the specified oil.
4. Install and tighten the fill plug to 35-50 lb-ft (47-68
N•m).
!
T
T
T
T
Figure 7
Section 2
Removal and Installation
FILL
PLUG
DRAIN
PLUG
T-2111 SHOWN (TYPICAL)
•
•
•
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Page 9
Section 3
Disassembly
Disassemble Parking Brake
WARNING
To prevent serious eye injury, always wear safe eye
protection when doing maintenance or service.
WARNING
Some brake linings contain asbestos fibers, a
cancer and lung disease hazard. Some brake
linings contain non-asbestos fibers whose long
term effects are unknown. Caution should be
exercised in handling both asbestos and non-
asbestos materials as described on page 2.
1. Remove transfer case from vehicle as described
on page 7.
2. Rotate the transfer case in the repair stand so that
the brake is facing upward.
3. Remove the output flange or yoke nut.
4. Lift the brake drum and flange assembly from the
output shaft. If necessary, remove the brake drum
from the flange.
NOTE:
•
Match mark the brake drum and flange so these
parts can be put together in the same position at
assembly.
•
Refer to Figure 8 to disassemble the parking
brake.
5. Use a brake shoe return spring removal tool to
remove the brake shoe return springs (3) from the
ends of the brake shoes (7). Discard the springs
and replace them with new springs at reassembly.
6. Remove both brake shoes and mark them to identify
their original position so that they are installed in the
same position at reassembly.
7. Lift the actuator strut (8) from the brake backing
plate (2).
NOTE:
Make a note of how the brake backing plate is
mounted. Use the position of the camshaft as the
reference point.
8. Remove the four brake backing plate mounting
capscrews. Lift the backing plate and adapter
assembly from the output shaft.
9. Remove the nut (5) and washer (6) that hold the
camshaft to the brake lever (4). Remove the
camshaft (1) and lever.
10. Remove the oil slinger and oil seal from the
adapter.
Figure 8
1. CAMSHAFT
2. BACKING PLATE ASSY.
3. SHOE RETURN SPRINGS
4. BRAKE LEVER
5. LOCK NUT
6. WASHER
7. BRAKE SHOE & LINING ASSY.
8. ACTUATOR STRUT
!
!
DCM BRAKE
1
87
6
5
4
3
3
2
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

Page 10
Disassemble Proportional
Differential
NOTE:
Refer to Figure 9 to disassemble the proportional
differential.
1. Remove the differential bearing cage-to-cover
capscrews and washers. Lift the bearing cage and
shaft assembly from the transfer case.
2. Remove the snap ring and the ring gear from the
shaft.
3. Remove the shaft, bearing cones and spacers. Press
the shaft out toward the large end of the bearing
housing.
4. Use a bearing puller to remove the bearing cups
from the housing.
5. Remove the sun gear from the front output shaft.
6. Remove the snap ring from the rear output shaft.
Remove the planetary spider assembly and spacer.
Disassemble Planetary
Spider Assembly
1. Remove the snap ring from the ends of the planet
shafts.
2. Remove the thrust washer and planet gear from the
planet shafts.
3. Remove the set screws from the planet shafts.
4. Press the planet pins out of the spider. Use care
when handling the planet pins. If the nylon coating
on the pin is cut, the pin must be discarded.
Figure 9
Section 3
Disassembly
REAR
OUTPUT
FRONT
OUTPUT
BRAKE
ADAPTER
SPACERS
PLANET
SHAFT
DIFF. BRG.
CAGE
PLANET
GEAR
SUN
GEAR
RING
GEAR SET
SCREW
PLANETARY
SPIDER
SPACER
◄
►
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

Page 11
Section 3
Disassembly
Disassemble Yokes from
Input and Output Shafts
1. Rotate the transfer case in the repair stand so the
yokes face upward.
2. Remove the yoke nuts and washers from the input
and output shafts.
3. Remove the yokes from the output shafts.
NOTE:
Do not remove the oil slinger from the yoke or
flange unless it is damaged.
Disassemble Bearing Cages
from Front Half Side
1. Match mark the bearing cages and transfer case
housing so that they can be put together in the same
position at reassembly. Figure 10.
2. Remove the capscrews and washers that attach the
bearing cages to the transfer case housing.
CAUTION
Be careful not to damage the shims when
removing the bearing cage. Damaged shims can
cause fluid leakage.
3. Lift the bearing cage and shim pack from both shafts.
Keep the shim packs for use at reassembly.
Figure 11.
Figure 10
Figure 11
!
MATCH
MARKS
SHIM
PACK
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

Page 12
Disassemble Declutch
Assembly
5450 ft. lb. (7400 N•m) Version: Figure 12.
CAUTION
Be careful not to damage the shims when
removing the bearing cage. Damaged shims can
cause fluid leakage.
11. Lift the bearing cage and shaft assembly from the
housing. If there are any shims in between the
transfer case housing and bearing cage, keep
them. You will use these shims at assembly.
Replace damaged or worn shims.
12. Remove the oil and dirt seals from the bearing cage
assembly.
13. Remove the ball bearing retention snap ring.
14. Remove the declutch output shaft and ball bearing
assembly in the direction of the oil seal and snap
ring bores.
15. Remove the sliding declutch collar.
16. Remove the ball bearing from the declutch output
shaft.
NOTE:
Continue with steps 17 and 18 for “full torque”
version.
11,000 ft. lb. (14900 N•m) “Full Torque” Version:
Figure 13.
Figure 12
Figure 13
1. Rotate the transfer case in the repair stand so that
the declutch assembly is facing upward.
2. If the declutch assembly has a declutch indicator
switch, remove the declutch indicator switch from the
shift plate.
3. Remove the capscrews and washers from the
declutch shift plate. Remove the plate.
4. Remove the setscrew from the declutch shift fork.
5. Remove the capscrews and washers from the cover
of the declutch piston. Remove the cover.
6. Remove the declutch piston and the return spring.
7. Remove the quad seal from the declutch piston.
Discard the quad seal. Install a new quad at
assembly.
8. Remove the shift fork.
9. Remove the two internal output cage mounting
capscrews and washers.
10. Remove the external output cage mounting
capscrews and washers.
17. Remove the quad ring seal from the declutch
bearing cage bore for the air piston shaft.
18. Remove the needle bearing from the bore of the
declutch output shaft.
!
Section 3
Disassembly
OUTPUT
SHIFT
FORK
DRIVEN
SHAFT
DECLUTCH
COLLAR
BALL
BEARING
OUTPUT
CAGE
OIL
SEAL
DECLUTCH
OUTPUT
SHAFT
SHIFT
PLATE SET
SCREW
PISTON
PISTON
COVER
DECLUTCH
SHAFT ROLLER
BEARING
DECLUTCH
INDICATOR
SWITCH
(OPTIONAL)
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

Section 3
Disassembly
Page 13
Disassemble Proportional
Differential Lockout and
Front Output Shaft Assembly
1. Rotate the transfer case in the repair stand so that
the declutch assembly is facing upward. Figure 14.
2. If the declutch assembly has a declutch indicator
switch, remove the declutch indicator switch from the
shift plate.
3. Remove the capscrews and washers from the
declutch shift plate.
4. Remove the setscrew from the declutch shift fork.
5. Remove the capscrews and washers from the cover
of the declutch piston. Remove the cover.
6. Remove the declutch piston and the return spring.
7. Remove the quad seal from the declutch piston.
Discard the quad seal. Install a new quad seal at
assembly.
8. Remove the shift fork.
9. Remove the two internal output cage mounting
capscrews and washers.
10. Remove the external output cage mounting
capscrews and washers.
CAUTION
Be careful not to damage the shims when
removing the bearing cage. Damaged shims can
cause fluid leakage.
11. Lift the bearing cage and shaft assembly from the
housing. If there are any shims in between the
transfer case housing and bearing cage, keep
them. You will use these shims at assembly.
Replace damaged or worn shims.
12. Remove the oil and dirt seals from the bearing cage
assembly.
13. Remove the ball bearing retention snap ring.
14. Remove the declutch output shaft and ball bearing
assembly in the direction of the oil seal and snap
ring bores.
!
15. Remove the sliding declutch collar.
16. Remove the ball bearing from the declutch output
shaft.
Disassemble Housing Halves
1. Remove the bolt, washers and nuts from the outer
flange of the housing.
2. Separate the case halves with a pry bar. Figure 14.
Figure 14
WARNING
To avoid serious personal injury and possible
damage to components, be very careful when
using lifting devices.
•
Inspect to make sure that the lifting loops or
lifting straps are not damaged.
•
Always use both lifting loops and lifting straps
when lifting.
•
Do not subject lifting loops or lifting straps to any
shock or drop loading.
3. Use the lifting loops or eyebolts to lift and remove the
top half of the case.
!
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]

Page 14
4. Lift and remove the three gear and shaft assemblies
from the bottom of the case. Figure 15.
Figure 15
5. Remove the output shaft bearing cup from the lower
housing half.
Disassemble Bearing Cages
and Differential Cover from
Housing
1. Rotate the case half in the work stand so the bearing
cages face upward.
2. Match mark the bearing cages and the housing so
that they can be reassembled in the same position.
3. Remove the capscrews and washers from the
differential cover. Remove the cover.
4. Remove the capscrews and washers from the input
and idler shaft bearing cages.
5. To loosen the bearing cages from the housing, hit
the cage with a soft mallet from inside the housing.
6. Remove the bearing cages from the housing.
NOTE:
There are no shims under the bearing cages on
this side of the housing.
Section 3
Disassembly
Disassemble Idler Gear, Input
and Output Shaft Assemblies
1. Use a bearing puller to remove the bearing cones
from the idler gear assembly.
Disassemble Input and Idler
Shaft Bearing Cages
1. Remove and discard the oil seal from the input
bearing cage.
2. Use a bearing puller to remove the bearing cups
from the input shaft and idler shaft bearing cages.
WARNING
Observe all WARNINGS and CAUTIONS provided
by the press manufacturer concerning press
operation to avoid serious personal injury and
possible damage to components.
2. Use a hydraulic press with the correct support blocks
to press the input and output shafts out of the gears
and bearing cones.
!
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 [phone] / [phone] • [email protected]