29-3. TRANSFER CASE REPAIR
This task covers:
a. Disassembly
c. Inspection and Repair
b. Cleaning
d. Assembly
a. Disassembly
1.
Remove capscrew (1), clamp (2), pinion adapter (6), and driven gear (4) from rear retainer (5).
2.
Remove O-ring (3) from pinion adapter (6). Discard O-ring (3).
3.
Remove nut (7), front output yoke (8), and lockwasher seal (9) from transfer case (11). Discard
lockwasher seal (9).
4.
Move shift range lever (10) to most rear position.
5.
Remove three capscrews (12) from rear extension (14) and rear retainer (5).
CAUTION
Do not pry or wedge rear extension from rear retainer. Sealing
surfaces could be damaged.
6.
Use a soft-nosed hammer or mallet on screw hole bosses (15) on rear extension (14) to break sealing
bead and remove rear extension (14) from rear retainer (5).
7.
Remove rear output shaft seal (13) from rear extension (14). Discard rear output shaft seal (13).
INITIAL SETUP:
Tools
____
General mechanic’s tool kit:
automotive (Appendix B, Item 1)
Maintenance and repair shop equipment:
automotive (Appendix B, Item 2)
Screw extractor set (Appendix B, Item 98)
Arbor press (Appendix B, Item 111)
Special Tools
__________
Slide hammer adapter (Appendix B, Item 83)
Driver handle (Appendix B, Item 60)
Input gear seal installer (Appendix B, Item 87)
Output shaft front bearing installer
(Appendix B, Item 88)
Output shaft front bearing remover
(Appendix B, Item 89)
Extension housing bushing remover
(Appendix B, Item 91)
Bushing remover/bearing installer
(Appendix B, Item 85)
Extension housing seal installer
(Appendix B, Item 93)
Bearing inserter (Appendix B, Item 92)
Mainshaft pilot bearing installer
(Appendix B, Item 86)
Seal installer (Appendix B, Item 95)
Seal installer (Appendix B, Item 96)
Materials/Parts
_____________
O-ring seal (Appendix G, Item 284)
Two O-rings (Appendix G, Item 277)
Washer seal (Appendix G, Item 436)
Oil tube seal (Appendix G, Item 420)
Poppet spring seal (Appendix G, Item 409)
Input seal (Appendix G, Item 405)
Oil seal (Appendix G, Item 412)
Rear output seal (Appendix G, Item 419)
Tapered drive pin (Appendix G, Item 299)
Anaerobic gasket sealer (Appendix C, Item 58)
Petrolatum (Appendix C, Item 52)
Adhesive sealant (Appendix C, Item 4)
Sealing compound (Appendix C, Item 64)
Transmission fluid (Appendix C, Item 37)
Transfer case support stand (Appendix D, Fig. 64)
Silicone sealant (RTV) (Appendix C, Item 74)
Manual References
________________
TM 9-2320-387-24P
Equipment Condition
_________________
Transfer case removed (para. 20-3).
Maintenance Level
_______________
General support
TM 9-2320-387-24-2
29-2
Change 1
