Copyright Meritor, Inc., 2015

(16579)
Printed in USA

앫 For new design carriers: Keep the adjusting ring for
reuse.

— For old design carriers: Install kit 2920.
— For new design carriers: Install kit 2935.
앫 If the red pre-grease is not washed out of the area between
the primary and secondary seal lips and this is a repeat
adjusting ring leak repair: Perform the following.
— For old design carriers: Install a new cover using the Cover
Retrofit Procedure in this bulletin. Use KIT 2936 for a
non-pumped version or KIT 2937 for a pumped version.

7.

On new design carriers, remove the O-ring from the adjusting
ring and inspect it for damage. Replace it if necessary after the
adjusting ring has been cleaned. Also, check the carrier bore
for burrs and remove them if necessary.

8.

Use brake cleaner to clean the threads of the adjusting ring.
Ensure the threads are dry before applying the sealant.
NOTE: For new design carriers, do not allow brake cleaner to
come into contact with the O-ring.

— For new design carriers: Contact the Meritor OnTrac™
Customer Call Center at 866-668-7221 for additional
guidance.

NOTE: Suitable tools for cleaning the cover threads are picks,
small wire brushes, cleaning solvents such as brake cleaner
and compressed air.

Leak Repair Procedure
1.
2.

Wear safe eye protection. Park the vehicle on a level surface.
Block the wheels to prevent the vehicle from moving.

9.

Install a dial indicator and position the tip on the end of the
input shaft. Check and record the input shaft end play.
Figure 10.

Figure 10

Place a rag in the carrier cover opening to prevent debris from
entering the bearing area during the cleaning process. Use a
pick or other suitable tool to clean the old sealant from the axle
carrier mating threads in the cover. Do not use air tools to clean
the threads. After the old sealant is removed, use brake
cleaner to thoroughly clean the cover threads and allow the
threads to dry. Figure 11.

Figure 11

Clean old sealant
from threads.

CARRIER
COVER

1002577c

4009826b

Figure 11

Figure 10

3.

Remove the yoke nut and yoke from the input shaft.

4.

Clean any debris surrounding the adjusting ring prior to
removal to ensure none enters the axle.

5.

Remove the bolt from the lock plate and remove the lock plate
from the adjusting ring.

6.

Remove the adjusting ring from the cover. An air hammer with
a blunt tip can be used to facilitate removal of the adjusting
ring.

10. On old design carriers, ensure the threads of the new adjusting
ring and the carrier cover are clean and dry. Apply Loctite 577
thread sealant included in kit 2920 to the entire circumference
of the input bearing adjusting ring and the axle carrier cover.
Make sure to embed the Loctite 577 thread sealant into the
threads thoroughly. Loctite 565 thread sealant can be used
as a substitute if necessary.

앫 For old design carriers: Discard the adjusting ring.

(16579)
Printed in USA

Copyright Meritor, Inc., 2015

TP-1214
Revised 03-15
Page 5

11. On new design carriers, apply a small amount of axle oil to the
O-ring and to the O-ring sealing journal inside the carrier cover.
Use only the amount of oil necessary to lubricate the O-ring
and journal to prevent excess oil from spreading to other parts.
Install the O-ring on the adjusting ring. Ensure the threads of
the adjusting ring and the carrier cover are clean and dry.
Apply thread sealant, part number 2297H8406, included in kit
2935 to the outside diameter of the input bearing adjusting
ring. Figure 12.

Figure 13

Figure 12

ADJUSTING RING
NEW
DESIGN
COVER

O-RING GROOVE
O-RING

4009856a

O-RING SEALING
JOURNAL
Figure 13

4011816a

14. Clean the threads on the lock plate bolt. Apply Loctite 242
threadlocker to the bolt. Install the lock plate and bolt. Tighten
the bolt to 25 lb-ft (34 N폷m). @

Figure 12

15. Remove the old sleeve from the yoke and install a new sleeve.
Refer to the Seal Replacement Procedure for complete
instructions.

CAUTION
On new design carriers, do not allow the O-ring on the
adjusting ring to come into contact with the threaded portion
of the cover. Damage to the O-ring can result.
NOTE: Use care to avoid overtightening the adjusting ring.
12. Install the adjusting ring into the cover. Tighten the adjusting
ring using a target torque of 15-20 lb-ft (20-27 N폷m). This
range will bottom out the adjusting ring and seat the cup and
bearings in the ideal position to obtain correct end play. Do not
exceed 20 lb-ft (27 N폷m). Rotate the input shaft back and forth
to further ensure the bearing is seated. Then, back the
adjusting ring out two notches.
NOTE: The yoke does not have to be installed during this step.
13. Check the input shaft end play according to the instructions in
Maintenance Manual MM-0970. If necessary, loosen or tighten
the adjusting ring one notch to adjust the end play to
0.002-0.008-inch (0.05-0.20 mm).

16. Install the new seal into the adjusting ring using Meritor seal
driver 2728T1 and a dead blow hammer until it is completely
seated. Refer to the Seal Replacement Procedure for complete
instructions. When correctly seated, there should be less than
a 0.010-inch (0.25 mm) gap between the seal flange and
adjusting ring. Use care to keep the seal lips clean during this
step and the rest of the procedure. Figure 21.
17. Apply Loctite 270 or 277 threadlocker in a 0.12-inch
(3.1 mm) bead around the inside diameter of the yoke nut.
18. Install the yoke and yoke nut on the input shaft. Refer to the
Seal Replacement Procedure for complete instructions. Tighten
the yoke nut to 800 ± 45 lb-ft (1090 ± 60 N폷m). @
19. Wait two hours after final assembly before you operate the
vehicle to allow the sealant to cure.

앫 To move the bearing cup outboard: Place one end of a
pry bar under the yoke nut and apply force by hand on the
other end to pull the input shaft outward. Figure 13.

TP-1214
Revised 03-15
Page 6

Copyright Meritor, Inc., 2015

(16579)
Printed in USA

Seal Replacement Procedure

Figure 16

ADJUSTING
RING

Removal
1.

SEAL

PRY
TOOL

Use the correct tool to hold the input yoke in place. Remove the
input yoke nut and washer. Figure 14.

Figure 14

4008186a
Figure 16

4.

Remove the sleeve from the yoke.

Installation
1002725c

1.

Clean the ground and polished surface of the yoke journal
using a clean shop towel and a safe cleaning solvent. Do not
use abrasive cleaners, towels or scrubbers to clean the yoke or
flange surface. Do not use gasoline.

2.

Inspect the yoke seal area for damage that could cause
lubricant leaks after you install the seal. Use emery paper or an
equivalent product to remove scratches, nicks or burrs only.

3.

Install the deflector, if equipped, onto the yoke. You must install
the deflector before you install the sleeve onto the yoke.
Figure 17.

Figure 14

2.

Use a yoke puller or other suitable tool to remove the yoke from
the input shaft. Figure 15.

Figure 15

YOKE
PULLER

Figure 17

1002733c

YOKE

Figure 15

DEFLECTOR,
IF EQUIPPED

CAUTION

SLEEVE

Carefully remove the oil seal from the adjusting ring. Do not
damage the seal bore when you remove the seal. Damage to
components can result.
3.

Pry under the oil seal flange to remove the oil seal from the
adjusting ring. Discard the oil seal. Figure 16.

(16579)
Printed in USA

DRIVER

4004889a

Figure 17

4.

Apply a light coat of axle oil to the yoke journal. Position the
sleeve into the forward-rear axle input yoke sleeve driver. Do
not touch the greased areas of the sleeve. The sleeve must be
kept clean prior to assembly into the seal. Use an arbor press
and Meritor sleeve driver 2728T2 to install the sleeve into the
yoke. Verify that the sleeve is fully-seated in the yoke.
Figure 18.

Copyright Meritor, Inc., 2015

TP-1214
Revised 03-15
Page 7

The yoke must be fully pressed into the sleeve driver until the
end of the yoke bottoms out in the sleeve driver. This will
correctly position the sleeve on the yoke. When correctly
seated, the forward-rear input sleeve is positioned 0.030-inch
(0.75 mm) from the end of the yoke.
앫 If you do not have a press: Position the yoke on a
five-inch (127 mm) spacer on a workbench. Use a
dead-blow hammer and the appropriate driver to install the
sleeve into the yoke.

6.

Use a feeler gauge to check the gap between the seal and the
adjusting ring. The seal is correctly installed if the gap is less
than 0.010-inch (0.25 mm) around the circumference of the
seal flange. Figure 20 and Figure 21.
앫 If the gap is more than 0.010-inch (0.25 mm): Use a
dead-blow hammer and the appropriate driver to
completely install the seal.

Figure 20

Figure 18

FORWARD-REAR INPUT
WITH DEFLECTOR

SLEEVE
4004875a
Figure 18

4004877b

CAUTION

Figure 20

Hold the sleeve and seal only on the outer diameter. Do not
touch the greased inner diameter of the seal and the greased
area of the sleeve. This can contaminate the seal and cause a
leak between the shaft and the seal. Damage to components
can result.
5.

Figure 21

SEAL

Install the forward-rear axle input seal. Hold the sleeve and
seal only on the outer diameter. Position the seal into the seal
driver and align it with the adjusting ring on the forward-rear
axle cover. Do not touch the lips in the inner diameter of the
seal. Use a dead-blow hammer and Meritor seal driver 2728T1
to install the seal into the adjusting ring. Figure 19.

Measure
the gap.

4008186b

Figure 19

Figure 21

FORWARD-REAR INPUT

Yoke Installation
CAUTION
Use a press and a sleeve or yoke installation tool to install the
yoke. Do not use a hammer or mallet. Using a hammer or
mallet can damage the bearings, yoke or flange.
1.

4004876c

Use a press and sleeve or special yoke/flange driver tool, SPX
Kent-Moore part number J 48718, to install the yoke or flange.
Do not use the nut to draw on the yoke or flange. The yoke or
flange must be seated against the outer bearing. If a press and
sleeve are used, verify that the input shaft is well supported.
Figure 22.

Figure 19

TP-1214
Revised 03-15
Page 8

Copyright Meritor, Inc., 2015

(16579)
Printed in USA

2.

Figure 22

Remove the O-ring from the groove around the IAD piston on
the housing face. Figure 24.

Figure 24

IAD
PISTON

4008100b
O-RING

Figure 22

4008192b

2.

Install a yoke bar or other suitable tool to hold the yoke in
place. Figure 23.

Figure 23

Figure 24

3.

Install a new O-ring of the same thickness as the one removed.
The kit provides two O-rings of different thicknesses, 0.07″
(1.78 mm) and 0.21″ (5.33 mm). Use the O-ring that fits the
carrier you are servicing.

4.

Install the new cover according to procedures in Maintenance
Manual MM-0970.

5.

Follow the procedure in Maintenance Manual MM-0970 to
install the new adjusting ring and adjust the input bearing end
play EXCEPT for the following.

1002725c
Figure 23

3.

4.

Apply Loctite 270 or 277 threadlocker in a 0.12-inch
(3.1 mm) bead around the inside diameter of the yoke nut.
Install the washer and yoke nut onto the input shaft and tighten
to 800 ± 45 lb-ft (1090 ± 60 N폷m). Figure 23. @
Rotate the input shaft one complete turn to seat the bearings.

Cover Retrofit Procedure
6.
NOTE: Follow the correct instructions for “Pump” or “Non-Pump”
carriers when referring to procedures in Maintenance Manual
MM-0970.
1.

A.

It is not necessary to clean the new parts.

B.

Install the O-ring around the new adjusting ring.

C.

Do not apply surface primer to the adjusting ring threads
and the threaded surface for the adjusting ring on the
cover.

D.

Use sealant 2297H8406 from the kit when you are
instructed to apply sealant to the adjusting ring. Apply
sealant only to the outside diameter of the adjusting ring.
Do not apply sealant to the threads in the cover.

Install the seal and yoke according to procedures in
Maintenance Manual MM-0970.

Remove the carrier cover. Refer to Maintenance Manual
MM-0970 for complete procedures.

Meritor Heavy Vehicle Systems, LLC
2135 West Maple Road
Troy, MI 48084 USA
866-OnTrac1 (668-7221)
meritor.com

Information contained in this publication was in effect at the time the publication was approved for printing and is subject to
change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the information presented or
to discontinue the production of parts described at any time.
Copyright 2015
Meritor, Inc.
All Rights Reserved

Printed in USA

TP-1214
Revised 03-15
(16579)