TM 9-2320-307-24-2
I
29-3. TRANSFER CASE REPAIR (Cont’d)
1
15.
16.
Inspect range shift fork (16) for burrs, bends, and breaks. Remove burrs. Replace pads (6) if there is
any wear. Replace range shift fork (16) if broken, cracked, loose pin (15) or damaged.
Inspect range clutch sleeve (17) and mode shift sleeve (7) for burrs, cracks, breaks, and damaged
splines or gear teeth. Remove minor burrs. Replace range clutch sleeve (17) or mode shift sleeve (7) if
damaged.
17.
Inspect mode shift fork assembly (8) for cracks, breaks, bent brackets (2) and (141, and broken or
deformed springs (4) and (10). If pads (6) are worn, replace pads (6). Replace bracket (14) if pin (1) is
damaged. Mode shift fork assembly (8) must slide freely on shift rail (18) without excessive side free
play. Inspect two bushings (5) for damage. Replace bushings (5) if damaged. If free play is excessive,
replace mode shift fork assembly (8).
(a) Disassemble mode shift fork assembly (8) as follows:
(1)
(2)
(3)
(4)
(5)
Position mode shift fork assembly (8) in vise with bracket (14) secured in vise.
NOTE
Mode shift fork assembly is under spring tension. Use care when
compressing fork to release bracket.
Press mode shift fork (8) down and tilt to free and remove mode shift fork assembly (8) from
bracket (14).
Remove bushing (111, spring (lo), and thrust washer (9) from mode shift fork (8).
Remove bracket (21, cup (3), and spring (4) from mode shift fork (8).
Remove bracket (14) from vise.
(b) Assemble mode shift fork assembly (8) as follows:
ci)
(2)
Install bracket (14) in vise.
(3)
(4)
(5)
(6)
Install spring (41, cup (31, and bracket (2) on short end of mode shift fork (8). Ensure open end of
bracket (2) is positioned under mode shift fork lip (12).
Install thrust washer (91, spring (lo), and bushing.111) on mode shift fork (8).
Position mode shift fork assembly (8) on bracket (14).
Press mode shift fork (8) down and forward until tab (13) on bracket (2) is seated in bracket (14).
Remove mode shift fork assembly (8) from vise.
18.
19.
Inspect shift rail (18) for bends, cracks, and grooving. Replace shift rail (18) if damaged.
Inspect detent assembly for broken or kinked spring (20), broken or burred poppet (191, or damaged
plug (22). Replace poppet spring seal (21) on plug (22). Replace plug (22), spring (20), or poppet (19)
if damaged.
20.
21.
22.
23.
24.
Inspect drive chain (23) for breaks, missing parts, kinks, and evidence of scratching on contact
surfaces. Replace drive chain (23) if damaged.
Inspect drive sprocket (24) and driven gear (26) for cracks, breaks, bent or twisted splines, and
broken or chipped gear teeth. Replace gears (24) or (26) if damaged.
Inspect front output shaft (25) for cracks, bent or twisted splines, damaged threads, and scored
bearing and sealing surfaces. Minor scoring and thread damage is repairable. Replace front output
shaft (25) if damaged.
Inspect low-range gear (29) for cracks, breaks, chipped or broken gear teeth, pinion side free play
and smooth rotation. If front and rear carriers are loose, tighten screws (28); if still loose, replace
low-range gear (29). For all other damage, replace low-range gear (29).
Inspect oil cooler (27) for bends, breaks, and leaks. Repair by straightening bent fins. Replace oil
cooler (27) if damaged.
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29-18
