Meritor MTC-4208X Series, Service Manual, Page: 76 / 120

Copyright Meritor, Inc., 2020
MM-0861 / Revised July 2020
Page 72
Printed in USA
6 Assembly
7. Use a feeler gauge to check the seal gap. The seal is correctly
installed if the gap is less than 0.005” (0.127 mm) around the
circumference of the seal fl ange.
If the gap is more than 0.005” (0.127 mm): Use a dead-blow
hammer and the appropriate driver to completely install the seal.
8. Clean the splines of the old Silastic before installing the yoke.
Apply a light coat of transfer case oil to the yoke seal journal and
then use a mallet to install the yoke.
9. Verify the yoke is fully seated on the input shaft.
10. Apply a 1/8” (3.175 mm) bead of Silastic RTV 732 sealant 360 °
around the underside of the washer. Figure 6.38.
Figure 6.38
4006411a
SPLINE
UNDERCUT
YOKE
WASHER
YOKE
NUT
SEALANT
11. Install the rear output shaft yoke washer and new yoke nut.
Tighten the nut to 700-900 lb-ft (949-1220 N∙m).
Front Axle Shift Cylinder
1. Rotate the transfer case to install the front axle shift cylinder.
2. Remove the front axle shift cylinder used to temporarily hold the
shift shaft in place.
3. Grease the o-ring on the piston and install the piston into the
cylinder.
4. Apply a 1/8” (3 mm) bead of Loctite 277 sealant to the fi rst three
threads of the shift cylinder.
5. Install and tighten the shift cylinder to 80-100 lb-ft (108-136
N∙m).
Output Shaft Oil Seal & Yoke
For all transfer cases: Install the input seal and sleeve using Meritor
kits 2728T1 and 2728T2 respectively. Install the forward output shaft
seal using Meritor Kit 4454.
For MTC-4208X/XL/XP/XLEV & MTC-4210X/XL/XP/XLEV trans-
fer cases:
Install the rear output shaft seal using Meritor Kit 4454.
For MTC-4213X transfer case: Install the rear output shaft seal
using Meritor Kit 4454.
1. Install the front output shaft oil seal using the appropriate seal
driver. Drive the seal until it is fully seated. Figure 6.39.
Figure 6.39
4000210a
2. Apply a light coat of transfer case oil to the yoke journal. Install
the front output yoke, washer and new yoke nut. Tighten the yoke
nut to 700-900 lb-ft (949–1220 N∙m).
3. Repeat Steps 1 and 2 for the rear output seal and yoke.
4. Once fi nal assembly of the transfer case has been completed and
the yokes have been installed, remeasure the input and output
yoke end plays to ensure they are within specifi cation.