TM 9-2320-387-24-2
1 20-3. TRANSFER CASE REPLACEMENT
1
This task covers:
a. Removal
b. Installation
INITIAL SETUP:
Tools
General mechanic’s tool kit:
automotive (Appendix B, Item 1)
Special Tools
Torque adapter, 9/16-in.
(Appendix B, Item 133)
Materials/Parts
Six locknuts (Appendix G, Item 1’72)
Four lockwashers (Appendix G, Item 206)
Cotter pin (Appendix G, Item 27)
Anaerobic gasket sealer
(Appendix C, Item 58)
Personnel Required
One mechanic
One assistant
Manual References
TM 9-2320-387-24P
Equipment Condition
l Muffler and catalytic converter removed
(para. 3-49).
l Mumer support bracket removed (para. 3-55).
General Safety Instructions
l Allow transfer case to cool before performing
this task.
l Transfer case must be supported during removal
and installation.
Maintenance Level
Direct support
a. Removal
1.
Remove drainplug
(4) from transfer case (1). Allow fluid to drain and install drainplug (4). Tighten
drainplug (4) to 35 lb-ft (47 Nom).
2.
3.
4.
Remove four nuts (12), lockwashers (13), two U-bolts (14), and front propeller shaft (15) from
transfer case yoke (11). Discard lockwashers (13).
Disconnect vent line (5) from adapter (8) on transfer case (1).
Disconnect 90” speedometer cable adapter (7) from transfer case (1) and remove cable adapter (7)
with speedometer cable (6).
5.
Remove rear propeller shaft (3) from transfer case housing (2).
6.
Loosen two hose clamps (9) and disconnect rubber cooling lines (10) from transfer case (1).
WARNING
Allow transfer case to cool before performing this task. Failure to
do this may cause injury to personnel.
CAUTION
Cover or plug all open lines and connections immediately after
disconnection to prevent contamination. Remove all plugs prior to
connection.
20-2
