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TB-9-2320-335-13&P HMMWV Operator and Field Maintenance, Parts, Tools M1151A1 M1152A1 M1165A1 Download

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20-3.1. TRANSFER CASE REPLACEMENT (SERIAL NUMBERS 300000 AND ABOVE) TB 9-2320-335-13&P 20-2 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 A, Item 114.2) Four lockwashers (Appendix A, Item 145) Cotter pin (Appendix A, Item 21) Tiedown strap (Appendix A, Item 324) Anaerobic gasket sealer (Appendix C, Item 58) Personnel Required One mechanic One assistant Manual References TM 9-2320-387-24-1 TM 9-2320-387-24P Equipment Condition • Muffler and catalytic converter removed (TM 9-2320-387-24-1). • Muffler support bracket removed (TM 9-2320-387-24-1). • Transfer case guide cable removed (TM 9-2320-387-24-2). General Safety Instructions • Allow transfer case to cool before performing this task. • Transfer case must be supported during removal and installation. Maintenance Level Direct support 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). a. Removal