SERVICE PARTS MANUAL FOR T SERIES

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1 SERVICE PARTS MANUAL FOR 420 SERIES Rev: 1 Date: 10/08/12 MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com

2 TABLE OF CONTENTS REPLACEMENT PARTS & WARRANTY CLAIM PROCEDURE...3 COMPLETE TRANSFER CASE MODEL IDENTIFICATION....5 FLANGE IDENTIFICATION... 6 FRONT HOUSING DTC FLANGE ADAPTER FRONT HOUSING TUBING REAR HOUSING INPUT SHAFT COVER INTERMEDIATE SHAFT COVER DTC INPUT SHAFT RTC INPUT SHAFT INTERMEDIATE SHAFT OUTPUT SHAFT NON-PD OUTPUT SHAFT PD OPTION PLANETARY DIFFERENTIAL HI-LO SHIFTING FRONT DECLUTCH ASSEMBLY PARKING BRAKE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com - 2 -

3 REPLACEMENT PARTS When ordering replacement parts for MARMON- HERRINGTON TRANSFER CASES, the following information should be given: 1. FACTORY ORDER NUMBER. Found on ID Plate affixed to Transfer Case Housing. This will be a six (6) digit number. (See illustration below) 2. Model of transfer case, i.e T-30, T Give quantity and complete part number including ALL CHARACTERS (including zeros (0), dashes (-), underscores (_), and spaces). Note: Drivelines, shift linkages, etc., can be found on the computer printout of Bill of Material, which is included in the Service Manual. 4. Give complete billing and shipping address. 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 and obtain a Repair Authorization number. Please be prepared to supply all of the following information: Factory Order Number- This is located on an ID plate fixed to either the driver s door panel or the component (axle or transfer case) itself. Model and Serial Number (Required)- Again located on the ID plate fixed to either the driver s door panel or the component itself. Vehicle year, Make and Model Vehicle Identification Number Mileage In Service Date EXAMPLE PART NUMBERS _333_233 MUST BE INCLUDED MUST BE INCLUDED The information necessary for replacement parts and/or warranty claim procedures will be found on the ID Plate SXXXX XX - 3 -

4 - 4 - SERIES -420

5 - 5 -

6 - 6 -

7 This Page Left Intentionally Blank - 7 -

8 - 8 - DTC FLANGE

9 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY DTC Adapter Flange Stud M12x Washer M Nut M12x Bolt M12x60 14 MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com DTC FLANGE - 9 -

10 FRONT HOUSING

11 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY DTC Front Housing 1 *Option 1007 RTC Front Housing 1 *OPTIONAL-EXTERNAL COOLER Breather Filter Check Valve RZ Plug Screw M30x Reducer Sealing Ring A30x Retaining Ring 27x Plug Screw M14x Sealing Ring A22x Sealing Ring A14x Pressure Relief Valve Restrictor Plug Check Valve RV Sealing Ring A22x Plug Screw M22x T Seal, Inner 120x100x T Seal, Outer 120x100x Seal Holder Plug Screw M18x Sealing Ring A18x Nut M26x Adjuster Screw Drain Plug Magnetic M22x1.5 1 MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com FRONT HOUSING

12 FRONT HOUSING TUBING

13 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY DTC Front Housing 1 *Option 1007 RTC Front Housing O-Ring 7x Fitting, 18mm Oil Pickup Tube Tube Clamp Bolt M8x Plug Screw M12x Sealing Ring A12x Swivel Fitting, 90 degree Fitting, Straight Tube, Cross-over Tube, Short 1 MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com FRONT HOUSING TUBING

14 REAR HOUSING

15 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY Rear Housing Washer, Wave M Bolt M12x Plug Screw M10x Sealing Ring A10x Plug Screw M22x Sealing Ring A22x Dowel Pin M6x Oil Deflector Non-PD 1 *PD Option 1052 Oil Deflector With PD Swivel Fitting, 90 degree Tube Sprayer Tube Fitting, Straight Retaining Ring 21x Sealing Ring A16x Pressure Relief Valve 1 MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com REAR HOUSING

16 INPUT SHAFT COVER

17 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY Input Cover Plate Bolt M12x Sealing Ring A10x Plug Screw M10x Oil Tube Input Shaft Detent Ball mm NSS NSS=Not Sold Seperately MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com INPUT SHAFT COVER

18 INTERMEDIATE SHAFT COVER

19 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY Bolt M12x Intermediate Shaft Cover Sealing Ring A18x Plug Screw M18x Speed Sensor 1 WITHOUT SPEED SENSOR Sealing Ring A18x Plug Screw M18x1.5 1 MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com INTERMEDIATE SHAFT COVER

20 DTC INPUT SHAFT

21 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY Groove Nut M Bolt M14x Bearing 140x80x Washer, Input Shaft Thrust Washer 7mm O-Ring 55x Drive Gear 46T O-Ring Input Shaft Connection Flange Coupler Drive Gear 30T Thrust Washer 10mm Bearing 125x70x Groove Nut M Guide Bushing A Shim 124.8x110x0.15 AR 1082B Shim 124.8x110x0.2 AR 1083C Shim 124.8x110x0.3 AR 1082D Shim 1248x110x0.7 AR 1082E Shim 124.8x110x1.5 AR AR=As Required MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com DTC INPUT SHAFT

22 RTC INPUT SHAFT

23 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY Bearing 140x80x Thrust Washer 7mm Drive Gear 46T Input Shaft Coupler Drive Gear 30T Thrust Washer 10mm Bearing 125x70x Groove Nut M Guide Bushing A Shim 124.8x110x0.15 AR 1082B Shim 124.8x110x0.2 AR 1083C Shim 124.8x110x0.3 AR 1082D Shim 1248x110x0.7 AR 1082E Shim 124.8x110x1.5 AR Flange Washer Bolt M16x70 1 AR=As Required MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com RTC INPUT SHAFT

24 INTERMEDIATE SHAFT

25 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY Oil Pump Bolt M5x Bearing 125x70x Intermediate Shaft Bearing 125x70x A Shim 124.8x110x0.15 AR 1082B Shim 124.8x110x0.2 AR 1083C Shim 124.8x110x0.3 AR 1082D Shim 1248x110x0.7 AR 1082E Shim 124.8x110x1.5 AR Groove Nut M Key A4x4x10 1 AR=As Required MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com INTERMEDIATE SHAFT

26 OUTPUT SHAFT NON-PD

27 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY Bearing 180x120x Output Shaft 50T (Non-PD) Bearing 125x70x A Shim 124.8x110x0.15 AR 1082B Shim 124.8x110x0.2 AR 1083C Shim 124.8x110x0.3 AR 1082D Shim 124.8x110x0.7 AR 1082E Shim 124.8x110x1.5 AR Seal, Inner 105x85x Seal, Outer 105x85x Output Cover Rear Non-PD Bolt M12x Flange Washer Bolt M16x70 1 AS=As Required MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com OUTPUT SHAFT NON-PD

28 OUTPUT SHAFT PD OPTION

29 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY Bearing 180x120x Countersunk Screw M8x Labyrinth Ring Bearing 125x70x Seal, Inner 105x85x Seal, Outer 105x85x A Shim 179.5x160x0.7 AR 1141B Shim 179.5x160x0.3 AR 1141C Shim 179.5x160x0.2 AR 1141D Shim 179.5x160x0.15 AR Output Cover Rear PD Bolt M12x Flange Washer Bolt M16x70 1 AR=As Required MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com OUTPUT SHAFT PD OPTION

30 PLANETARY DIFFERENTIAL

31 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY Planetary Differential, Complete Differential Housing Rear Bolt M10x Planetary Carrier Assembly (INCLUDES ITEM 11, QTY. 8) Thrust Washer Planetary Pin Needle Bearing Planetary Gear Cylindrical Pin 17x Toothed Ring Retaining Spring Retaining Pin M6x Bolt M10x Bearing 85x45x Retaining Ring AV Oil Tube Ring Gear Output Shaft PD Retaining Ring SB180 1 MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com PLANETARY DIFFERENTIAL

32 HI-LO SHIFTING

33 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY Slide Block A Shim, 25x18x0.2 AR Shift Fork B Shim, 25x18x0.3 AR Bolt M10x C Shim, 25x18x0.5 AR O-Ring 7x D Shim, 25x18x1.0 AR Shift Rod O-Ring 65x O-Ring 13.3x Piston Piston, Neutral Shift Cylinder O-Ring 74x O-Ring 26x Piston, Road O-Ring 57x Nut M18x O-Ring 5x Shift Cover Bolt M10x Pressure Switch Sealing Ring A18x Switch Pin Adjuster Screw 1 AR=As Required Nut M26x1.5 1 MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com HI-LO SHIFTING

34 FRONT DECLUTCH ASSEMBLY

35 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY Front Declutch Housing Front Output Shaft Non-PD Jam Nut M16x1.5 1 *PD OPTION 1214 Front Output Shaft PD Sealing Ring A12x Coupler, Output Shaft Plug Screw M12x Retaining Ring 120x Pressure Switch Bearing 120x65x Switch Pin Seal, Inner 105x85x Guide Sleeve Seal, Outer 105x85x Sealing Ring A18x Bolt M12x Spring, Front Axle Flange Washer O-Ring 20x Bolt M16x Shift Fork, Front Axle Piston, Front Axle 1 COMPLETE ASSEMBLIES O-Ring 52x3 1 Does NOT Include Items 5,6,7,8,25,26, Dowel Pin M6x Control Rod, Front Axle O-Ring 5x Bolt M10x Intermediate Plate Front Declutch Assembly Without PD Front Declutch Assembly With PD MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com FRONT DECLUTCH ASSEMBLY

36 PARKING BRAKE

37 ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY Bolt M16x Mechanical Caliper B (Shown) Mechanical Caliper A Hydraulic Caliper Caliper Spacer Parking Brake Rotor Bolt M12x Dowel Pin M6x KV 150 Output Flange Parking Brake Lock Nut M12x Flange Washer Bolt M16x70 1 MARMON-HERRINGTON ALL-WHEEL DRIVE Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com PARKING BRAKE

38 Magisterial Drive Louisville, KY (502) * (800) * Fax (502) info@marmon-herrington.com

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