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PM06/05
MARMON-HERRINGTON ALL-WHEEL DRIVE13001 Magisterial Drive • Louisville, KY 40223
(502) 253-0277 • (800) 227-0727 • Fax (502) 253-0317E-mail: [email protected]
PARTS MANUALFOR
MVG754 TRANSFER CASE
FORWARDWARRANTY POLICY AND PROCEDURE . . . . . . . . . . . . . . . . . . . . 3-5
MVG754 TRANSFER CASEHOUSING MVG754 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
INPUT SHAFT, COVER MVG754 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
DOUBLE GEAR MVG754 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
OUTPUT SHAFT MVG754 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
OUTPUT SHAFT, SHIFTING MVG754 . . . . . . . . . . . . . . . . . . . . . 14-15
FLANGE MVG754 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17
HIGH, LOW GEAR SHIFTING MVG754 . . . . . . . . . . . . . . . . . . . . 18-19
LUBRICATION, PIPE, VALVE MVG754 . . . . . . . . . . . . . . . . . . . . 20-21
PM06/05
— 2 —
MARMON-HERRINGTON ALL-WHEEL DRIVE13001 Magisterial Drive • Louisville, KY 40223(502) 253-0277 • (800) 227-0727 • Fax (502) 253-0317E-mail: [email protected]
TABLE OF CONTENTS
— 3 —
GENERAL
This manual has been prepared for operators and servicepersonnel working with the Marmon-Herrington series of trans-fer cases and front drive axles. For further technical assistance,please contact Marmon-Herrington Customer Service.
Please observe and follow all procedural and maintenanceguidelines to ensure reliable operation and optimum service life.The Marmon-Herrington basic service schedule will integrateseamlessly with most preventative maintenance programs.
Marmon-Herrington shall not be liable for component failures ordamages caused by operational abuse or neglect. Pleasereview the Warranty Statement for a detailed explanation ofcoverage and claim reporting procedures.
We thank you for your investment in Marmon-Herringtonequipment, and look forward to serving your needs in thetradition of engineering excellence.
MISCELLANEOUS ISSUES
Tires and Gear Ratios
When vehicles are still in the specification stage prior toconstruction, a great deal of thought and calculation goes intodetermining what tires and gear ratios will be best suited tothe engine and transmission combination being used. This isespecially true of AWD (all-wheel-drive) type vehiclesbecause front and rear drive axles are interconnected throughthe transfer case, and therefore vulnerable to the adverseeffects of differential tire speed. The most prominent of theseadverse conditions is called “wind-up” which is caused by“ratio mis-match.”
Effectively, this means that by virtue of different tire sizes orgear ratios from front to rear, one set of tires is trying to turnfaster than the other. This generates excessive amounts oftorque (wind-up) which is transmitted through the drive train.These extreme torsional loads can cause damage to differentialgears, transfer cases, even engines and transmissions.
With the preceding in mind, it behooves the owner or operatorto seek expert advice when considering alternative gear ratiosor tires.
Operations
1) USE OF AWD MODE
Your Marmon-Herrington transfer case or axle may find itselfpaired with a front drive axle in an AWD application aspreviously described. If so, there are a few points ofoperational practice that will ensure a long, trouble free servicelife. In the tire and ratio discussion we demonstrated onesource of drive train wind-up, and some of the undesirableeffects. The same consequences may be experienced throughyet a different mode of abuse.
As close as engineers try to match gear ratios and tires for agiven application, the reality is that there will always be somedegree of mis-match between front and rear axles. When avehicle is operated on a hard, dry surface with the front axleengaged (AWD, 4x4, 6x6, etc.), the tires are not able to slipand relieving the torsional forces being generated.
As such, Marmon-Herrington equipped vehicles are designedfor “as needed” AWD operation, only in “off-road” conditions.They are not intended to be driven in AWD mode on hard, drysurfaces.
2) SHIFTING OF AXLE OR TRANSFER CASE
Marmon-Herrington Axles and Transfer Cases use noclutching devises, and therefore should only be shifted whenthe vehicle is at a full stop. This applies to front axleengagement, high and low ranges, and locking differentials.The only exceptions are those vehicles equipped withMarmon-Herrington’s Safety-Shift system, which arecalibrated to shift up to 4 mph.
SAFETY-SHIFT
Marmon-Herrington Transfer Cases do not employ any clutchingdevice, and therefore are not of a class that may be shifted “onthe fly”, or when the vehicle is in motion. This applies to shiftingbetween HIGH and LOW ranges as well as engaging the frontaxle. Shifting on the fly results in two different types of internaland external damage. The first is degradation of the engage-ment teeth due to relative rotation of drive gears and shiftcollars. This type of damage can prevent the case from shiftingnormally, as the teeth become burred and cannot mesh.
The second condition imparts excessive shock loading through-out the entire drive train. This occurs when a shift is attemptedat the precise moment of tooth alignment (gears meshing), andthe shift is actually completed at excessive speed. This resultsin high torque loading that is transmitted through the transfercase, drive shafts, and axles.The extent of the damage possibleincreases proportionately with the vehicle speed.
Over the years we have tried to protect end users from thismode of failure with operational placards, audible warnings,and light signals. Despite these efforts, we have yet to fullydiscourage this destructive practice.
In December 2003 Marmon-Herrington developed an electronicmanagement system called Safe-T-Shift to help prevent shift onthe fly events. It consists of a microprocessor that receivesspeed information from a remote sensor in the transfer case.The system is calibrated to activate the shift solenoids at the firstdetection of motion, and then cancel control functions at 4 mph.
The actual completion of a shift still relies on tooth alignment ofthe gear sets, and the vehicle may need to roll a few feet beforethe transfer case can shift. Because the system becomes activeat first motion and maintains air pressure thereafter, it ispossible to accelerate rapidly to a speed greater than 4 mphbefore tooth alignment occurs, completing the shift. In thiscase, the shift may occur at a speed great enough to causeshock damage. For this reason, it is essential that the operatorlet the vehicle “walk” or idle forward until the shift is completebefore accelerating normally.
Shift Procedure
1. With the vehicle at a complete stop, select the desired rangeor front axle position.
2. Place the main transmission in gear.
3. Allow the vehicle to idle forward (or backwards) at walkingspeed until shift is completed.
4. Accelerate normally.
In the case of a manual transmission, ease the clutch out in lowgear, allowing the vehicle to “walk” until shift is completed.
Some possible exclusions to the Safe-T-Shift program are thosevehicles fitted with a transfer case mounted PTO, Freightlinerfactory conversions, and any with Rockwell transfer cases.
REV 05/05
FORWARD
REV 05/05
— 4 —
MARMON-HERRINGTON WARRANTY
This is to certify that we, Marmon-Herrington Company,Louisville, Kentucky, warrant each new chassis remanu-factured, or assembly or part furnished for the remanufacture ofa truck chassis against defects in material and workmanshipunder normal use and service. Marmon-Herrington’s obligationunder this warranty is limited to replacement of, at our factory,any part or parts thereof which shall, within one (1) year afterdelivery of such vehicle to the final user after installation of theall-wheel drive conversion kit, be returned to us with trans-portation charges prepaid, and which our examination shalldisclose to our satisfaction to have been thus defective.
Marmon-Herrington will warrant covered components againstdefects in material and workmanship under normal use andservice for the specified period. This warranty includes allinternal components with the following exceptions: Exceptionsinclude, but are not limited to wear items such as brake liningsand drums, oil seals and bearings, which will be covered for aperiod of 12 months or 12,000 miles, which ever occurs first.
Failure to follow designated maintenance procedures andschedules, maintain required lubrication levels, or any form ofoperational abuse or misuse will void all warranty coverageexpressed or implied.
Failure reporting and claims submission procedures are to befollowed as outlined in the standard warranty guidelines
Service parts are manufactured to the same standards asproduction installed parts. However, since the installationthereof, as well as the age and condition of the receivingvehicle are beyond the control of Marmon-Herrington, ServiceParts are warranted for a period of ninety (90) days or fivethousand (5,000) miles whichever first occurs. All other regularwarranty conditions apply.
On vehicles operating OVERSEAS, the determination of defectswill be made at Marmon-Herrington Company, Louisville,Kentucky, from complete information supplied in writing byoverseas 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, dateof breakage, type of service, nature of break or fault, distributor’srecommendation (for our guidance only), and any otherpertinent information. After determination of our obligation, anyparts to be replaced will be shipped to distributor or actingdistributor in accordance with his instructions.
This warranty is in lieu of all other warranties expressed orimplied and of all other obligations or liabilities incurred byMarmon-Herrington. Marmon-Herrington neither assumes norauthorizes any other person to assume any other liability inconnection with this sale, including but not limited to indirect orconsequential damages.
This warranty shall not apply to any vehicle which shall havebeen repaired or altered in any way so as in our judgment, toaffect its stability or reliability, nor which has been subject tomisuse, negligence, or accident, nor which shall have beenoperated at a speed exceeding the factory rated speed orloaded beyond the factory rated load capacity or operated inviolation of Marmon-Herrington’s instructions.
Marmon-Herrington makes no warranty whatever oncomponents 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 bytheir respective manufacturers.
The manufacturers reserve the right to make changes indesign, and changes or improvements upon their product,without notice, and without incurring any obligation to installsuch changes or improvements upon their products theretoforemanufactured.
This warranty shall become effective only when the WarrantyCertificate has been returned to Marmon-Herrington andvalidated by the same.
In the case of vehicles operating in extreme conditions such ascorrosive material mines, deep- water zones or areas of hostileaggression, the following warranty limitations apply:
Marmon-Herrington shall not be responsible for damage causedby chemical corrosion, internal water damage due to totalimmersion, or explosive impact. These conditions constitutesevere duty and are not covered by Marmon-Herringtonstandard warranty.
WARRANTY REPAIR AND CLAIM PROCEDURE
Initial Failure Reporting
1. Operator must call Marmon-Herrington Customer Serviceprior to performing any repairs and receive a RepairAuthorization Number to be eligible for reimbursement. Thework authorization number does not guarantee payment butis an acknowledgement that the vehicle is within thewarranty period in terms of date and mileage, and that aclaim has been activated. It will be the responsibility ofthe operator to ensure that their repair facility is awareof and complies with the guidelines of this policy.
2. To expedite the authorization process, you will need theSales Order Number or “S” number found on the front of thiscertificate. You will also need the Vehicle IdentificationNumber or the last six digits of the “VIN”, the date the vehiclewas placed in service, and the current mileage. Please notethe following:• This Warranty Registration should have been submitted at
the time of delivery. If our records do not include a warrantyregistration, you must complete one before any authori-zation for repair can be issued. We will make themavailable by mail or fax upon request.
3. Marmon-Herrington will pre-approve .5 hours diagnosis/inspection time prior to your call for repair authorization. Ifthe the diagnosis/inspection complaint does not reveal awarrantable failure, or result in a warrantable repair, thecustomer will be responsible for all charges includingdiagnosis/inspection time.
4. The Operators Manual contains information covering properequipment use and maintenance schedules. Operators mustadhere to these guidelines to be eligible for reimbursement,and service records must be provided upon request.
Pre-Repair Requirements
1. Authorization for repairs will require a written estimate/repairorder of costs after determination that a warrantablecondition is found to exist.
— 5 —REV 05/05
2. Estimates must contain the following information:• A list of all parts necessary for specific job and if applicable,
all parts that will be invoiced back to Marmon-Herrington.• The cost of disassembly, inspection and diagnosis of any
portion of the vehicle to determine extent of repairs needed.• Current labor costs, reflecting both hourly rate and number
of hours to effect repairs must be listed.• Miscellaneous charges such as “shop supplies” must be
defined. Actual dollar amounts must be listed, as percen-tages will not be accepted.
• Sublet repairs must also be defined and included in theestimate at their actual dollar amount.
• NOTE: If it becomes necessary to exceed the originalestimate in terms of parts or labor, the repair facility mustcall Marmon-Herrington Customer Service for additionalauthorization.
3. Only the use of Marmon-Herrington supplied parts willconstitute reimbursement unless prior approval has beenobtained.
Parts Ordering
While Marmon-Herrington operates a full service PartsDepartment, replacement parts needed to effect Warrantyrepairs must be acquired through Customer Service to beeligible for reimbursement.
Post Repair Requirements
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 thetransfer case or axle.
• The Axle or Transfer Case Model and Serial Number, alsolocated 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 belisted as separate line items and shown on the final invoiceas stated in “Pre-Repair Requirements.” Invoices for subletrepairs must be made available upon request.
2. All repairs must comply with any or all state and DOTrequirements.
3. Downtime of vehicle and incurred costs associated due tothe delay of parts shipments or any other condition beyondour control is not reimbursable and should not be listed onthe invoice.
4. 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 replacementparts when shipped from Marmon-Herrington.
5. All Claims must be submitted within 60 days of completionof repairs to be eligible for reimbursement.
For Work Authorization call: (800) 227-0727, Ext. 282To Submit Claims by Fax: (502) 253-0317
Submit Claims by Mail to:Marmon-Herrington Company, Customer Service Department,13001 Magisterial Drive, Louisville, KY 40223.
REPLACEMENT PARTSWhen ordering replacement parts for MARMON-HERRINGTONLOW FLOOR conversions, the following information should begiven:
1. FACTORY ORDER NUMBER (found on I.D. Plate or smallplate affixed to axle housing).This will be a six (6) digit number.(See illustrations this page.)
2. Component for which parts are required, i.e. front drive axleor transfer case/drop box.
3. Model of axle and/or transfer case/drop box, i.e. MT10, MVG750, MDB500.
4. Give quantity and part number required. NOTE: Drivelines,shift linkage, etc., can be found on the computer printout ofBill of Material, which is included in the Service Manual.
5. Give complete billing and shipping address.
WARRANTY CLAIM PROCEDUREBefore proceeding with repairs or ordering parts that you feelmay be covered under warranty, you must first contactMarmon-Herrington Customer Service Department to obtain aRepair Authorization Number.
(800) 227-0727, Ext. 282 8am-5pm EST(502) 693-1129 5pm-8pm EST
Please be prepared to supply the following information:
Factory Order Number or “S-Number” This is located onan ID plate fixed to either the driver’s door panel or thecomponent (axle or transfer case) itself. This plate will alsoshow the component’s model and serial number. Example:S-7777-05
Component Model and Serial NumberVehicle Year, Make and ModelVehicle Identification NumberMileageIn Service Date
Please refer to our website (www.marmon-herrington.com) forthe latest versions of our parts and service manuals, as well asnew products and contact information.
The information necessary for replacement parts and/orwarranty claim procedures will be found on either platedesign.will be found on either plate design.
FACTORYORDER NO.
INSTALLEDBY
FRONT DRIVING AXLE
MODEL
CAPACITY
SERIAL NO.
RATIO
TRANSFER CASE
MODEL
SERIAL NO.
LOUISVILLE, KENTUCKY U.S.A.
PM09/03
0000-00
MARMON-HERRINGTONSALES ORDERS/NCUST P/N
RATIOTYPE
0000-00
MARMON-HERRINGTONSALES ORDERS/NCUST P/N
TYPE
0000-00
COVERED BY ONE OR MORE OF THE FOLLOWINGPATENTS: U.S. PATENTS 4,878,691; 4,934,733;
5,016,912; 5,275,430; 5,839,750; AND6,398,251; AND CA PATENT 1,316,185. OTHER
U.S. AND FOREIGN PATENTS PENDING.
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him
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MA
R
5M
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12-1
064A
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m,
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AR
MV
G12
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him
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R
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him
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5 M
MA
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6M
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75-1
316
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t O
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haft
1
7M
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75-1
080
Sle
eve
1
8M
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75-1
082
Ret
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1
9M
VG
75-1
081
Nee
dle
Sle
eve
1
10M
VG
75-1
072
Shi
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Sle
eve
1
11M
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75-1
071
Bal
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1
12M
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75-1
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Ret
aini
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1
13M
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75-1
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Sea
l, In
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1
14M
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75-1
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Sea
l, O
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1
15M
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75-1
107
Shi
ft F
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1
16M
VG
75-1
108
Pin
Rod
1
17M
VG
75-1
109
Pin
1
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75-1
110A
Shi
m R
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30x4
2x0.
1A
R
MV
G75
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him
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g,30
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MV
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him
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75-1
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O-R
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1
20M
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75-1
116
O-R
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1
21M
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75-1
115
Trea
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Pin
,M
10x1
21
22M
VG
75-1
008
Cov
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5008
88H
ex H
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Scr
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x35
3
24M
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75-1
117
Pre
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prin
g1
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75-1
118
Scr
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lug,
M18
x1.5
1
26M
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75-1
119
Bus
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Axl
e E
ngag
e1
27M
VG
75-1
120
Pin
1
28M
VG
12-1
125
Sna
p R
ing
1
29M
VG
12-1
040
Sea
ling
Rin
g1
30M
VG
75-1
127
Pre
ssur
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witc
h1
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= A
s R
equi
red
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M N
O.
MH
PA
RT
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CR
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NO
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T N
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SC
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TY.
RE
Q.
— 1
5 —
MA
RM
ON
-HE
RR
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TON
AL
L-W
HE
EL
DR
IVE
1300
1 M
agis
teria
l Driv
e •
Loui
svill
e, K
Y 4
0223
(502
) 25
3-02
77 •
(80
0) 2
27-0
727
• Fa
x (5
02)
253-
0317
E-m
ail:
info
@m
arm
on-h
erri
ngto
n.co
mP
M06
/05
OU
TP
UT
SH
AF
T,S
HIF
TIN
GM
VG
754
FL
AN
GE
MV
G75
4
— 1
6 —
PM
06/0
5
1M
T93
-132
4F
lang
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610
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1
2M
T93
-136
3F
lang
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710
Ser
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2
3M
VG
75-1
317
Fla
nge
Was
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3
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75-1
318
Fla
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Bol
t,M
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MH
PA
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CR
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QT
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— 1
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MA
RM
ON
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RR
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TON
AL
L-W
HE
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DR
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1300
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agis
teria
l Driv
e •
Loui
svill
e, K
Y 4
0223
(502
) 25
3-02
77 •
(80
0) 2
27-0
727
• Fa
x (5
02)
253-
0317
E-m
ail:
info
@m
arm
on-h
erri
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mP
M06
/05
FL
AN
GE
MV
G75
4
HIG
H, L
OW
GE
AR
SH
IFT
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MV
G75
4
— 1
8 —
PM
06/0
5
1M
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12-1
095
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319
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For
k1
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75-1
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Scr
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75-1
320
Shi
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Rod
1
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75-1
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1
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VG
75-1
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Cov
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711
5008
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ex H
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Scr
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M10
x35
3
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VG
75-1
322
Hex
Hea
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crew
,M
12x1
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01
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VG
75-1
103
Hex
Nut
,M
12x1
.51
10M
VG
75-1
095
Pis
ton
1
11M
VG
75-1
093
O-R
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1
12M
VG
12-1
036
O-R
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2
13M
VG
75-1
097
Pis
ton
1
14M
VG
12-1
001
Sna
p R
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1
15M
VG
75-1
105
Scr
ew P
lug,
M12
x1.5
1
16M
VG
12-1
112
Sea
ling
Rin
g1
17M
VG
75-1
111
Adj
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g S
crew
1
1811
5010
73H
ex N
ut,
M12
x1.5
1
19M
VG
75-1
112
Pin
1
20M
VG
75-1
096
Pre
ssur
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witc
h1
21M
VG
12-1
040
Gas
ket
1
ITE
M N
O.
MH
PA
RT
NO
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CR
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ION
QT
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EQ
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EM
NO
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H P
AR
T N
O.
DE
SC
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TIO
NQ
TY.
RE
Q.
— 1
9 —
HIG
H,L
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GE
AR
SH
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MV
G75
4
MA
RM
ON
-HE
RR
ING
TON
AL
L-W
HE
EL
DR
IVE
1300
1 M
agis
teria
l Driv
e •
Loui
svill
e, K
Y 4
0223
(502
) 25
3-02
77 •
(80
0) 2
27-0
727
• Fa
x (5
02)
253-
0317
E-m
ail:
info
@m
arm
on-h
erri
ngto
n.co
mP
M06
/05
LU
BR
ICA
TIO
N, P
IPE
, VA
LVE
MV
G75
4
PM
06/0
5
— 2
0 —
1M
VG
75-1
323
Inta
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1
2M
VG
75-1
324
Uni
on1
3M
VG
75-1
325
Sea
ling
Rin
g1
4M
VG
75-1
326
Ret
aini
ng S
trap
1
5M
VG
75-1
327
Hex
Hea
d B
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M8x
1x20
1
6M
VG
75-1
328
Was
her
1
7M
VG
75-1
329
Oil
Pip
e1
8M
VG
75-1
330
Sea
ling
Rin
g1
9M
VG
75-1
331
Oil
Pip
e,2-
45°
1
10M
VG
75-1
332
Elb
ow,
Oil
Pip
e2
11M
VG
75-1
333
Tee,
Oil
Pip
e1
12M
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75-1
334
Oil
Pip
e, 9
0°1
13M
VG
75-1
335
Spl
ash
Pip
e1
14M
VG
75-1
336
Byp
ass
Val
ve1
15M
VG
75-1
337
Sna
p R
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1
16M
VG
75-1
338
Spa
cer
1
ITE
M N
O.
MH
PA
RT
NO
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CR
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ION
QT
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EQ
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EM
NO
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H P
AR
T N
O.
DE
SC
RIP
TIO
NQ
TY.
RE
Q.
LU
BR
ICA
TIO
N,P
IPE
,VA
LVE
MV
G75
4
MA
RM
ON
-HE
RR
ING
TON
AL
L-W
HE
EL
DR
IVE
1300
1 M
agis
teria
l Driv
e •
Loui
svill
e, K
Y 4
0223
(502
) 25
3-02
77 •
(80
0) 2
27-0
727
• Fa
x (5
02)
253-
0317
E-m
ail:
info
@m
arm
on-h
erri
ngto
n.co
mP
M06
/05
— 2
1 —
PM06/05
13001 Magisterial Drive • Louisville, KY 40223
(502) 253-0277 • (800) 227-0727 • Fax (502) 253-0317
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