repair manual mvg-754 transfer case - Marmon
Contents
1. 2 300 Ma3x2 2 23 3 _ DEER o T 30 4 msx so maxis so w 3 maxs 30 l 4 3 CROSS SECTION VIEW Transfer gearbox VG 754 a JH La LS 0 VF Sg ep 2 7 SH LE d p sP ER 1 aa ae See dh B rite 2 lt n Ep Ee OA bzw SS Ce WwW Ss S p Pg ae e v Sab P gt fi 1 E am Zn is ER ae gd d lt ASS SST ca Se SG Se E 5 imi lt VG754_G04 ze SEX CONSUMABLES EN D D IN AA B1 Es E lt x S BE S 27 ey 275Nm 4 a 7 5 SE Lg SE Ar E D lt A 50t5Nm Yi di x CG ZU D2 Z JI 0 H B1 7 L e I GR Henk G1 Wes L AA eae SS Si 1 SSS Ye ee OC Ba oO N aes SEEK WA EEE SE 7 dt sum ees i B1 i Ve 1 Ss ES lt ERZ CEE N E 0 0 i 0 Nm VG 54_G06 CROSS SECTION VIEW Shifting VG 754 2 s E 9 SEN GEES 5 e te Se Cl SS ki Oo N GOEN EP ak z YA are SSS2. EES See SC x iZ W CES SR gt T SE SS Ee Wi ES Z BZ ZN NE om Ir N D D Si A NN LIS VG754_ G05 CONSUMABLES Consumables for repair of the transfer case are lubricants slip additives sealants locking adhesives preservatives and cleaning agents Table of consumables for unit repair FI Standard grease STABUTHERM GH 461 SUPEROL EP 2 Sealing compound DIRKO RHODORSEAL 3661 Adhesive Loctite 243 blue In the following diagram the greases anti seize agents sealing compounds and adhesives are indicated with their symbol and point to the components to be treated OIL CHANGE Oil change in warm condition Carefully clean all oil drain filling and level plugs before opening e Drain gear oil at drain plug 2 e Replace drain plug 2 with new seal e Fill with new gear oil at filling bore level bore 1 until it flows over e After correct oil filling replace level plug 1 with new seal Tightening torque MA 80 10 Nm Oil filling quantity app 8 5 litres Oil quality SAE 90 MIL L 2105 API GL4 tora Ste gt gt 2 2 VG 54_G07 LE C E T TI Y10772 11 12 1 DISASSEMBLING VG 754 Remove flange 1 Remove pipe 2 Remove flanges 1 1 Disassemble shifting road off road Remove cover Rebo
3. Marmon Herrington shall not be liable for component failures or damages caused by operational abuse or neglect Please review the Warranty Statement for a detailed explanation of coverage and claim reporting procedures We thank you for your investment in Marmon Herrington equipment and look forward to serving your needs in the tradition of engineering excellence MISCELLANEOUS ISSUES TIRES AND GEAR RATIOS When vehicles are still in the specification stage prior to construction a great deal of thought and calculation goes into determining what tires and gear ratios will be best suited to the engine and transmission combination being used This is especially true of AWD all wheel drive type vehicles because front and rear drive axles are interconnected through the transfer case and therefore vulnerable to the adverse effects of differential tire soeed The most prominent of these adverse conditions is called wind up which is caused by ratio mis match Effectively this means that by virtue of different tire sizes or gear ratios from front to rear one set of tires is trying to turn faster than the other This generates excessive amounts of torque wind up which is transmitted through the drive train These extreme torsional loads can cause damage to differential gears transfer cases even engines and transmissions With the preceding in mind it behooves the owner or operator to seek expert advice when considering alternative gea
4. cooled bearing outer rings or heat bearing area on the housing 1 use bearing 33 116 driver 5870 058 089 2 use bearing 33 116 driver 5870 058 9 3 use bearing 32 310 driver 1 SKO 102 979 4 use bearing 33 212 driver 1 SKO 102 979 2 1 Assembly input shaft Install shift fork and dog sleeve in housing Install input shaft Install input shaft in frozen condition stored at 25 C in a refridgerator Drive in input shaft and bearing with aluminium punch Install circlip Install shaft seals New shaft seals must be used Assure correct position of shaft seals see cross sectional view page 6 Ce Use Mandrel 1 SKO 102947 225105 Sketch for Mandrel 1 SKO 102947 220 130 110 10 2445 EE 7 ISESE 00060 SNE SN Eet o 94 o 74 8 o 72 o 63 ee Griffstiick gerandert Durchmesser 34 mm Changed handle Diameter 34 mm VG754_G02 80 WJ ES VG754_G_16 2 2 _ Assemble shifting front output shaft Mount oil dam into the hole of the input shaft Fix oil dam with LOCTITE 243 Note Mount the oil dam only in case of damage or when replacing the shaft and when cleaning the hole Mount gear pos 1 on shaft Oil bearing hole Heat bearing pos 2 to 80 C and mount Mount slotted nut pos 3 Use special tool A VG 750 09 Tightening torque 300 Nm Secure slotted nut stake 2 x Mount shifting s
5. housing Mount housing cover for bearing setting Do not seal mounting face Check rolling torque of the double gear Nominal rolling torque 20 35 Nm Use torque meter Correct any deviations from the nominal rolling torque by means of adjusting shims disassemble cover and bearing change adjusting shims Turn transfer box Insert assembly mandrel A VG 750 07 pos 1 and reseat until contact is obtained Check the rolling torque of the front axle output shaft arrow Nominal rolling torque 20 30 Nm Use torque meter 22 ES EE Engage FA gear shift system apply compressed air VG754_G_18 Setting and installation of gear shift system front axle output 7 H H P H 1 1 s SE Re N A eve ts oS HI Ta eer ra es Ui xA ZN A sS 222 Y Geier lu j E KR i 31 Measure distance X between assembly tube pos 1 and shift fork pos 3 Use depth gauge of the slide gauge pos 2 Reseat assembly mandrel A VG 750 07 pos 1 until contact is obtained j l KH E DN N et Le JE k 7 e VG754_G 0 Balance difference A with shim ring pos 1 Shim rings 30x 42x 0 1 30x 42x 0 2 30x 42x 0 5 30x 42x 1 0 Install O rings pos 1 on piston pos 2 Install shifting piston with seal Ce Grease sliding
6. sliding surface with gear oil Install intermediate shafts and output shaft Install oil guide Torque M8 8 8 MA 23 Nm Apply LOCTITE 518 on front housing 35 Install rear housing Torgues for tightening of housing bolts M10 MA 46 5 Nm M12 Ma 80 8 Nm Install bolts Torque M14 8 8 Ma 125 Nm Install oil guide 2 3 Assemble oil pump Mount oil pumpcover Pay attention to torsional stop slotted pin 36 Position drive ball into input shaft with grease Install ol pump gear on input shaft Ce Position of ball and groove must align Slide outer pump gear on oil pump gear Install 011 pump housing and tighten with Allen screws M 6x30 1 M 6x35 2 Torque M6 8 8 MA 9 5 Nm To avoid limiting pump axial clearance use silicone sealant 37 Install bearing cover Seal flange surface with LOCTITE 518 Torque MA 60 5 Nm Install cover Seal flange surface with LOCTITE 518 Tighten bolts with LOCTITE 243 Torque MA 60 5 Nm Setting and Installation of gear shift system on road gear off road gear 7 e Z Z lt d haer G VG754_G_24 2 4 Adjust high low gear Install piston with seal on shift rod CS Grease piston 38 Wa Slide cylinder and seal on shift rod Ee Grease cylinder Rebound circlip Install cover Ce Seal flange surface with LOCTITE 518 Torque Ma 46 5 Nm S
7. Before operating the transfer gearbox gear oil has to be filled according to the oil change instructions see page 9 Mount drain plug 2 with new seal Fill new oil at filling bore level bore 1 until it flows over e After correct oil filling mount level plug 1 with new seal Torque MA 80 10 Nm Oil filling quantity app 8 5 litres 27 oy Sen d A MES SH 8 H Weg D 2 VG754_G07 wa D 42 WARRANTY CLAIM PROCEDURE Before proceeding with repairs or ordering parts that you feel may be covered under warranty you must first contact Marmon Herrington Customer Service Department to obtain a Repair Au thorization Number 800 227 0727x282 8am 5pm EST 502 693 1129 50m 8pm EST Please be prepared to supply the following information Factory Order Number or S Number This is located on an ID plate fixed to either the driver s door panel or the component axle or transfer case itself This plate will also show the component s model and serialnumber Example S 7777 05 Component Model and Serial Number Vehicle Year Make and Model Vehicle Identification Number Mileage In Service Date Please refer to our website marmon herrington com forthe latest versions of our parts and service manuals aswell as new products and contact information WARRANTY REPAIR AND CLAIM PROCEDURE Initial Failure Reporting Operator must call Marmon Herrington Customer Ser
8. E mail info marmon herrington com egen ft lass 2 5 SS 1 i i VS rz PREFACE This service manual covers all phases of disassembly and repair of the MVG 754 The MVG 754 is a sophisticated gearbox demanding exacting tolerances of its precision assemblies Repairs should be conducted in a clean environment by experienced technicians All clearances and measurements should be considered critical and strictly adhered to When heating is required for disassembly torches and open flame type heat sources are prohibited Use only temperature controlled equipment All seals should be replaced during reassembly and bearings coated with prescribed lubricant Observe all torque specifications and adjustment data The MVG754 Parts Manual TCPM007 is a valuable reference during service or repair as it contains exploded component diagrams and part numbers A hard copy may be purchased from our parts department or a free copy may be downloaded from our website FOREWORD This manual has been prepared for operators and service personnel working with the Marmon Herrington series of transfer cases and front drive axles For further technical assistance please contact Marmon Herrington Customer Service Please observe and follow all procedural and maintenance guidelines to ensure reliable operation and optimum service life The Marmon Herrington basic service schedule will integrate seamlessly with most preventative maintenance programs
9. IFT Marmon Herrington Transfer Cases do not employ any clutching device and therefore are not of a class that may be shifted on the fly or when the vehicle is in motion This applies to shifting between HIGH and LOW ranges as well as engaging the front axle Shifting on the fly results in two different types of internal and external damage The first is degradation of the engagement teeth due to relative rotation of drive gears and shift collars This type of damage can prevent the case from shifting normally as the teeth become burred and cannot mesh The second condition imparts excessive shock loading throughout the entire drive train This occurs when a shift is attempted at the precise moment of tooth alignment gears meshing and the shift is actually completed at excessive speed This results in high torque loading that is transmitted through the transfer case drive shafts and axles The extent of the damage possible increases proportionately with the vehicle speed Over the years we have tried to protect end users from this mode of failure with operational placards audible warnings and light signals Despite these efforts we have yet to fully discourage this destructive practice In December 2003 Marmon Herrington developed an electronic management system called Safe T Shift to help prevent shift on the fly events It consists of a microprocessor that receives speed information from a remote sensor in the transfer case The sys
10. Marmon Herrington REPAIR MANUAL MVG 754 TRANSFER CASE MARMON HERRINGTON ALL WHEEL DRIVE 13001 Magisterial Drive Louisville KY 40223 502 253 0277 800 227 0727 Fax 502 253 0317 E mail info marmon herrington com Visit our web site to view Repair amp Parts Manuals www marmon herrington com TABLE OF CONTENTS Section No Page PREFACE 0 3 FOREWORD 59 Z ap cetera AA Aa AA 3 3 EE 4 TORQUE LIMITS FOR SCREWS u u wwa wai iwa uwa Aaa waa 7 CROSS SECTION OR er 8 10 Eegen 9 11 OIL CHANGE OIL FILLING QUANTITY OIL QUALITY 11 Chapter 1 DISASSEMBLY TRANSFER GEARBOX VG0G7154 T J J 1 12 fJ vU le e E 0 0 0 Ea aA 11 12 T2 CON 1 2 13 1 3 Front axle EE ld nuna nunu na nunu na u U nnmnnn nnmnnn mnnn J Q J J 1 3 18 UE WE SAI E 14 19 2 ASSEMBLY TRANSFER GEARBOX VG754 J J 21 2 OPU SNA E EEEE E E EEEO 2 1 21 22 Shin FON 2 2 22 ONL 2 3 26 24 Shifting road off road J 2 4 25 WARRANTY W 1 Marmon Herrington MARMON HERRINGTON ALL WHEEL DRIVE 13001 Magisterial Drive Louisville KY 40223 502 253 0277 e 800 227 0727 Fax 502 253 0317
11. e for reimbursement L Post Repair Reguirements 1 The final invoice or work order must include the following Customer s name address and phone number The Vehicle Identification number The Sales Order Number or S number which the customer can provide or can be located on the ID tag fixed to the transfer case or axle The Axle or Transfer Case Model and Serial Number also located on the ID tag Mileage IN Mileage Out The Cause and Correction of the repair including detailed description of repairs and parts replaced The date the repair order was open and the date the repairs were completed The Work Authorization Number obtained from Customer Service Notes to Repair Facilities 1 Miscellaneous charges such as shop supplies must be listed as separate line items and shown on the final invoice as stated in Pre Repair Reguirements Invoices for sublet repairs must be made available upon request All repairs must comply with any or all state and DOT requirements Downtime of vehicle and incurred costs associated due to the delay of parts shipments or any other condition beyond our control is not reimbursable and should not be listed on the invoice All failed parts that are required to be returned to Marmon Herrington must be received before payment will be made The Return Authorization will be sent with the replacement parts when shipped from Marmon Herrington All Claims must be submitted w
12. ere to these guidelines to be eligible for reimbursement and service records must be provided upon request Pre Repair Requirements 5 Authorization for repairs will require a written estimate repair order of costs after determination that a warrantable condition is found to exist 6 Estimates must contain the following information e Alist of all parts necessary for specific job and if applicable all parts that will be invoiced back to Marmon Herrington e Thecost of disassembly inspection and diagnosis of any portion of the vehicle to determine extent of repairs needed e Current labor costs reflecting both hourly rate and number of hours to effect repairs must be listed e Miscellaneous charges such as shop supplies must be defined Actual dollar amounts must be listed as percentages will not be accepted e Sublet repairs must also be defined and included in the estimate at their actual dollar amount e NOTE If it becomes necessary to exceed the original estimate in terms of parts or labor the repair facility must call Marmon Herrington Customer Service for additional authorization 3 Only the use of Marmon Herrington supplied parts will constitute reimbursement unless prior approval has been obtained Parts Ordering 1 if 4 d ki fi While Marmon Herrington operates a full service Parts Department replacement parts needed to effect Warranty repairs must be acquired through Customer Service to be eligibl
13. errington neither assumes nor authorizes any other person to assume any other liability in connection with this sale including but not limited to indirect or consequential damages This warranty shall not apply to any vehicle which shall have been repaired or altered in any way so as in our judgment to affect its stability or reliability nor which has been subject to misuse negligence or accident nor which shall have been operated at a speed exceeding the factory rated speed or loaded beyond the factory rated load capacity or operated in violation of Marmon Herrington s instructions Marmon Herrington makes no warranty whatever on components of the original manufacturer s chassis not related to the modification work Also no warranty is made on tires rims ignitions or other parts usually warranted separately by their respective manufacturers The manufacturers reserve the right to make changes in design and changes or improvements upon their product without notice and without incurring any obligation to install such changes or improvements upon their products theretofore manufactured This warranty shall become effective only when the Warranty Certificate has been returned to Marmon Herrington and validated by the same In the case of vehicles operating in extreme conditions such as corrosive material mines deep water zones or areas of hostile aggression the following warranty limitations apply Marmon Herrington shall not be re
14. etting of gear shift system Remove sealing agent residuals from the threaded holes Apply LOCTITE 243 onto the threads of the setting screws 1 and the lock nuts 2 and mount to flange 3 VG754 G 28 39 Es a A_ E st me me Fe vn TT 1 ka h Age e SES Zell Kb Sa E 7 WZ AZA VG7 54_G 4 EE Setting on road gear On road gear is actuated by supplying compressed air P 6 5 bar at connection A Bolt setting screw 1 into the shift cylinder until contact position with the shift rod is obtained Continue to turn the setting screw 1 3 to 1 2 revolution and secure with lock nut Setting off road gear Off road gear is actuated by supplying compressed air P 6 5 bar at connection B Bolt setting screw 2 into the flange until contact position with the shift rod is obtained Continue to turn the setting screw 1 3 to 1 2 revolution and secure with lock nut Install flanges and washer Apply LOCTITE 243 on flange surface of washer Mount screw Apply LOCTITE 243 on thread and friction surface of screws Torque MA 275 Nm 40 Install flanges and washer Apply LOCTITE 243 on flange surface of washer Mount screw Apply LOCTITE 243 on thread and friction surface of screws Torque Ma 275 Nm Install flange and washer Ce Apply LOCTITE 243 on flange surface of washer Mount screw LS Apply LOCTITE 243 on screws Torque MA 275 Nm
15. g fork and shifting dog sleeve KI VG754_G 06 5870 970 026 5870 970 026 incl oil pum For disassembly of the oil pump also refer to page 11 Remove bearing inner ring and shifting sleeve 1 5 Dismantle input shaft Remove bearing inner ring Dismantle the input shaft ass Pull off gear pos 1 Pull off gear pos 1 L Remove bearing outer rings from the housing arrow 5 5 O O 2 2 N N 5 5 Z Z x x S x 9 9 D 43 H d 0 Te ANA a a I N oe WW l A 7 Wi IN b yaa IA 7 7 3 if E Wee dE KW H E dee ee ef 77 KEEN 4 Ka H W SE N f eed 2 7 2 2 W x j SE AE E ju Se P Ki yA ee te be 0 De sie 21 ie V q d 1 6 Dismantle double gear f the double gear ing inner rings o Pull off bear Use KUKKO 18 2 extractor pos 1 5870 300 033 b and KUKKO 17 2 separating device pos 2 5870 300 038 Dismantle the double gear Remove the bearing outer rings from the housing arrows L Lg 2 ER a k y UN ege 2 LE Ge am my AE WA ce Ke EK Vi a dE NI x H e e E E Pe Mil oe TA 754 GO 22 r 1 1 7 _ Dismantle rear axle output shaft Pull off the front tapered roller bearing Use KUKKO 18 2 extract
16. ithin 60 days of completion of repairs to be eligible for reimbursement For Work Authorization call 800 227 0727 ext 282 To Submit Claims by Fax 502 253 0317 Submit Claims by Mail to Marmon Herrington Company Customer Service Department 13001 Magisterial Drive Louisville KY 40223 MARMON HERRINGTON WARRANTY This is to certify that we Marmon Herrington Company Louisville Kentucky warrant each new chassis remanufactured or assembly or part furnished for the remanufacture of a truck chassis against defects in material and workmanship under normal use and service Marmon Herrington s obligation under this warranty is limited to replacement of at our factory any part or parts thereof which shall within one 1 year after delivery of such vehicle to the final user after installation of the all wheel drive conversion kit be returned to us with transportation charges prepaid and which our examination shall disclose to our satisfaction to have been thus defective Marmon Herrington will warrant covered components against defects in material and workmanship un der normal use and service for the specified period This warranty includes all internal components with the following exceptions Exceptions include but are not limited to wear items such as brake linings and drums oil seals and bearings which will be covered for a period of 12 months or 12 000 miles which ever occurs first Failure to follow designated maintenance procedure
17. leeve pos 4 Oil teeth Mount gear pos 5 Heat bearing to 80 C pos 6 and mount Mount input shaft together with shift fork and shift rod Make sure that gear shift fork sliding pads are mounted correctly Oil shift rod on the sliding surface with transmission oil metten WOT54_G_25 Preassemble double gear Heat bearing on both sides to 80 C and mount Preassemble rear axle output shaft Heat bearing on both sides to 80 C and mount Preassemble front axle output shaft Heat bearing on both sides to 80 C and mount Mount suction line with fitting and spray tube Mount bypass valve arrow Secure with retaining ring 29 Make sure that the installation position of the bypass valve is correct Secure bypass valve with retaining ring Mount shaft seals pos 1 into housing cover Grease shaft seals with STABUTHERM Use driver 1 SKO 102977 Mount adjusting shims before installing the bearing outer rings Use basic disks as specified Mount bearing outer rings into the housing cover Mount super cooled bearing outer rings or heat bearing areas on the housing 1 use bearing 32 213 driver 1 SKO 102978 2 use bearing 32 213 driver 1 SKO 102978 3 use bearing 32 212 driver 1 SKO 102 979 4 use bearing 33 310 driver 1 SKO 102 979 30 Setting of bearings Setting double gear and front axle output shaft Mount preassembled double gear and front axle output shaft into
18. or pos 1 5870 300 033 and KUKKO 17 2 separating device pos 2 5870 300 038 Support with special tools A VG 750 06 and TS 214 W Pull off the rear tapered roller bearing Use two armed puller KUKKO 20 2 Dismantle rear axle output shaft Remove bearing outer rings from the housing arrows DEE SZ y 3 KS x A K N We AA ee sa EE V 4 oie SN La t WW a YA i S Sa 7 en Weien ANA DY L wf et ko r VG754_G_08 23 1 8 Dismantle front axle output shaft 1 Pull off the front tapered roller bearing N TS 214 W gt WE Ce Use KUKKO 18 2 extractor pos 1 5870 300 033 and KUKKO 17 2 separating device pos 2 5870 300 038 A VG 750 06 cn Support with special tools A VG 750 06 and TS 214 W VG754_48 Pull off the rear tapered roller bearing Ce Use two armed puller KUKKO 20 2 VG754_48 Dismantle the front axle output shaft Ce Remove bearing outer rings from housing arrows VOTS G D 24 RM WOTS4 5 1 9 Dismantle housing cover Unsnap retaining ring Remove bypass valve Remove suction line with fitting and spray tube from housing cover pos 1 Remove shaft seal pos 2 Remove all bearing outer rings from the housing cover Use two armed puller KUKKO 20 2 20 26 2 ASSEMBLY MVG 754 Mount bearing outer rings into housing Mount super
19. r ratios or tires OPERATIONS 1 USE OF AWD MODE Your Marmon Herrington transfer case or axle may find itself paired with a front drive axle in an AWD application as previously described If so there are a few points of operational practice that will ensure a long trouble free service life In the tire and ratio discussion we demonstrated one source of drive train wind up and some of the undesirable effects The same consequences may be experienced through yet a different mode of abuse As close as engineers try to match gear ratios and tires for a given application the reality is that there will always be some degree of mis match between front and rear axles When a vehicle is operated on a hard dry surface with the front axle engaged AWD 4X4 6X6 etc the tires are not able to slip and relieve the torsional forces being generated As such Marmon Herrington equipped vehicles are designed for as needed AWD operation only in off road conditions They are not intended to be driven in AWD mode on hard dry surfaces 2 SHIFTING OF AXLE OR TRANSFER CASE Marmon Herrington Axles and Transfer Cases use no clutching devises and therefore should only be shifted when the vehicle is at a full stop This applies to front axle engagement high and low ranges and locking differentials The only exceptions are those vehicles equipped with Marmon Herrington s Safety Shift system which are calibrated to shift up to 4 mph SAFETY SH
20. re special CAUTION references are given regarding special working procedures methods information use of auxiliaries etc This symbol points out situations where lacking care can lead to DANGER the injury of persons or damage to the product REFERENCE Prior to starting the checks and repair works thoroughly study the present instructions Illustrations drawings and parts do not always represent the original the working procedure is shown The numbering of illustrations e g HA754_01 is no consecutive numbering it is only used for archiving purposes No order can be derived out of it The illustrations drawings and parts are not true to scale conclusions regarding size and weight must not be drawn not even within one representation The works must be performed according to the description REFERENCE After the repair works and the checks the expert staff must convince itself that the product is properly functioning again TORQUE LIMITS FOR SCREWS in Nm according to ZF STANDARD 148 Coefficient of friction u total 0 12 for screws and nuts without after treatment as well as phosphated nuts Tightened by hand Torque limits can be taken from the following list unless otherwise specified in the repair instructions Metric ISO Standard Thread DIN 13 sheet 13 maxis CHO ER ESCHER EC M27x2 10 maxis so 23 max o 23 maxs o
21. s and schedules maintain required lubrication levels or any form of operational abuse or misuse will void all warranty coverage expressed or implied Failure reporting and claims submission procedures are to be followed as outlined in the standard war ranty guidelines Service parts are manufactured to the same standards as production installed parts However since the installation thereof as well as the age and condition of the receiving vehicle are beyond the control of Marmon Herrington Service Parts are warranted for a period of ninety 90 days or five thousand 5 000 miles whichever first occurs All other regular warranty conditions apply On vehicles operating OVERSEAS the determination of defects will be made at Marmon Herrington Company Louisville Kentucky from complete information supplied in writing by overseas distributors or recognized acting distributors Complete information is defined to mean vehicle serial number user s name date of delivery mileage at time of breakage date of breakage type of service nature of break or fault distributor s recommendation for our guidance only and any other pertinent information After determination of our obligation any parts to be replaced will be shipped to distributor or acting distributor in accordance with his instructions This warranty is in lieu of all other warranties expressed or implied and of all other obligations or liabilities incurred by Marmon Herrington Marmon H
22. sponsible for damage caused by chemical corrosion internal water damage due to total immersion or explosive impact These conditions constitute severe duty and are not covered by Marmon Herrington standard warranty Marmon Herrington 13001 Magisterial Drive Louisville KY 40223 502 253 0277 800 227 0727 Fax 502 253 0317 E mail info marmon herrington com Marmon Herrington Literature Order Form Credit Card Orders Or Current Customers Purchase Orders May Be Faxed 502 253 0317 STIS pon omy Pos Manos rm cm MVG 1200 Transfer Case TCSLO02 1200 Transfer Case 0000 600 Steg vm saras O foem mmm Repair Manuals zs LZ sus Kx mm re emmer 1 mmm ms Rss su Purchase Order P O only w current M H Account Mto MT2SAdes mmm uni Card Authorized Card User s Signature Operators Manuals Transfer Cases OM o Genera mer Sub Total Total Quantity Sales Literature KY Gales Tay Ship Order to the following address Standard Shipping Company TOTAL Due Name Telephone Number Address Fax Number City State Zip Code Country Postal Code PLEASE MAKE COPIES OF THIS LITERATURE ORDER FORM AS NEEDED Extended Cost No Charge No Charge 1 03 Marmon Herrington 13001 Magisterial Drive Louisville KY 40223 502 253 0277 800 227 0727 Fax 502 253 0317 E mail info marmon herrington com
23. surface and O rings mett tere Pre assemble cover and mount together with selector shaft into shift cylinder VG754_G_23 Mount cover L Secure screws with LOCTITE 243 Tightening torque M10 8 8 Ma 46 Nm Mount sliding bush pin and monitor switch 7 be ks For further assembly turn the transmission Disassemble housing cover Install sliding sleeve plug and control switch Ce Turn housing for further assembly 33 Slide in shaft spring 1 and plug Setting of rear axle output shaft and input shaft Mount preassembled rear axle output shaft and input shaft into housing Mount housing cover for setting of bearing L Do not seal mounting face Check the rolling torque of the rear axle output shaft Nominal rolling torque 20 35 Nm Ce Use torque meter Correct any deviations from the nominal rolling Ce torque by means of adjusting shims disassemble cover and bearing change adjusting shims Turn transfer box Check the rolling torque of the input shaft Nominal rolling torque 15 25 Nm Use torque meter Correct any deviations from the nominal rolling Ce torque by means of adjusting shims disassemble cover and bearing change adjusting shims Disassemble housing cover again 34 Install input shaft together with shifting fork and shift rod Ce Take care of correct positioning of sliders Ce Lube shifting rod at
24. tem is calibrated to activate the shift solenoids at the first detection of motion and then cancel control functions at 4 mph The actual completion of a shift still relies on tooth alignment of the gear sets and the vehicle may need to roll a few feet before the transfer case can shift Because the system becomes active at first motion and maintains air pressure thereafter it is possible to accelerate rapidly to a speed greater than 4 mph before tooth alignment occurs thus completing the shift In this case the shift may occur at a speed great enough to cause shock damage For this reason it is essential that the operator let the vehicle walk or idle forward until the shift is complete before accelerating normally 4 Shift Procedure 1 With the vehicle at a complete stop select the desired range or front axle position 2 Place the main transmission in gear 3 Allow the vehicle to idle forward or backwards at walking speed until shift is completed 4 Accelerate normally In the case of a manual transmission ease the clutch out in low gear allowing the vehicle to walk until shift is completed some possible exclusions to the Safe T Shift program are those vehicles fitted with a transfer case mounted PTO Freightliner factory conversions and any with Rockwell transfer cases k O1 The following safety references are used in the present Repair Manual This symbol is found in these repair instructions whe
25. und circlip Remove shift cylinder Pull off piston with sealing 12 Remove oil pump Loosen bolts Lift off cover 13 Loosen bolts Lift off housing cover Loosen Allen screws Lift off oil pump housing Ce Use pull screws Remove outer oil pump gear Remove oil pump gear Take out drive ball Ce By aid of magnet 1 Disassemble oil pump cover VG754_G_27 15 Disassemble anchor screws Disassemble oil tube Lift off rear housing Ce Use Pry bars Remove oil guide 16 Lift out intermediate shafts and output shaft Lift out input shaft together with shifting CS Attention be aware of sliders in the ends of shift fork Remove plug Remove plug and shift spring Ce Turn the housing for further disassembly 17 13 Remove front axle shifting Remove rear housing Remove cover and shifting shaft together Remove speedometer sending unit 1 Remove front axle lock control plug 2 with sliding sleeve and plug Remove shifting piston ce Discharge with compressed ar arrow Remove shifting piston with seal Dismantle the gear shift system front axle drive VG754_G_43 14 Removal of input shaft Remove shaft seals When shaft seals are being removed they must be replaced by new units Remove circlip 19 20 Va 3 Drive out front output shaft CS Use aluminium punch Remove shiftin
26. vice prior to performing any repairs and receive a Work Authorization Number to be eligible for reimbursement The work authorization number does not guarantee payment but is an acknowledgement that the vehicle is within the warranty period in terms of date and mileage and that a claim has been activated It will be the responsibility of the operator to ensure that their repair facility is aware of and complies with the guidelines of this policy To expedite the authorization process you will need the Sales Order Number or S number found on the front of this certificate You will also need the Vehicle Identification Number or the last six digits of the VIN the date the vehicle was placed in service and the current mileage Please note the following e This Warranty Registration should have been submitted at the time of delivery If our records do not include a warranty registration you must complete one before any authorization for repair can be issued We will make them available by mail or fax upon request Marmon Herrington will pre approve 5 hours diagnosis inspection time prior to your call for repair authorization If the diagnosis inspection complaint does not reveal a warrantable failure or result in a warrantable repair the customer will be responsible for all charges including diagnosis inspection time The Operators Manual contains information covering proper equipment use and maintenance schedules Operators must adh
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