TB 9-2320-335-13&P
20-3.1. TRANSFER CASE REPLACEMENT (SERIAL NUMBERS 300000 AND ABOVE)
This task covers:
a. Removal
b. Installation
INITIAL SETUP:
Tools
Manual References
General mechanic's tool kit:
TM 9-2320-387-24-1
automotive (Appendix B, Item 1)
TM 9-2320-387-24P
Special Tools
Equipment Condition
Torque adapter, 9/16-in.
Muffler and catalytic converter removed
(Appendix B, Item 133)
(TM 9-2320-387-24-1).
Muffler support bracket removed
Materials/Parts
(TM 9-2320-387-24-1).
Six locknuts (Appendix A, Item 114.2)
Transfer case guide cable removed
Four lockwashers (Appendix A, Item 145)
(TM 9-2320-387-24-2).
Cotter pin (Appendix A, Item 21)
General Safety Instructions
Tiedown strap (Appendix A, Item 324)
Anaerobic gasket sealer
Allow transfer case to cool before
(Appendix C, Item 58)
performing this task.
Transfer case must be supported during
Personnel Required
removal and installation.
One mechanic
Maintenance Level
One assistant
Direct support
a. Removal
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.
1.
Remove drain plug (8) from transfer case (1). Allow fluid to drain.
2.
Disconnect vent line (2) from transfer case (1).
3.
Remove four nuts (4), lockwashers (3), two U-bolts (6), and front propeller shaft (7) from transfer
case yoke (5). Discard lockwashers (3).
4.
Remove cotter pin (9), washer (10), and shaft linkage (12) from transfer case lever (11). Discard
cotter pin (9).
5.
Remove tiedown strap (14) from sender generator (13). Discard tiedown strap (14).
6.
Loosen nut (15) and remove sender generator (13) from transfer case (1).
7.
Disconnect two leads (17) from transfer case switch leads (16).
8.
Remove rear propeller shaft (18) from transfer case (1).
9.
Loosen two clamps (20) and remove coolant hoses (19) from transfer case (1).
10.
Remove transfer case switch (21) from transfer case (1).
20-2