TM-9-2320-280-34 HMMWV Direct Support & General Support Maintenance Manual Download
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TM 9-2320-280-34 8 - 3. TRANSFER CASE REPLACEMENT This task covers: a. Removal b. Installation INITIAL SETUP: Tools Manual References General mechanic's tool kit: TM 9-2320-280-20 automotive (Appendix G, Item 1) TM 9-2320-280-24P Special Tools Equipment Condition Torque adapter 9/16 in. * Muffler removed (TM 9-2320-280-20). (Appendix G, Item 106) * Muffler support bracket removed (TM 9-2320-280-20). Materials/Parts Six locknuts (Appendix E, Item 58) General Safety Instructions Four lockwashers (Appendix E, Item 82) * Allow transfer case to cool before performing Cotter pin (Appendix E, Item 8) this task. Anaerobic gasket sealer * Transfer case must be supported during removal (Appendix B, Item 45) and installation. Personnel Required Maintenance Level One mechanic Direct support One assistant a. Removal WARNING Allow transfer case to cool before performing this task. Failure to do this may cause injury. CAUTION Cover or plug all open lines and connections immediately after disconnection to prevent contamination. Remove all plugs prior to connection. NOTE • Transfer case replacement procedure for the M1097, 'A1 and “A2" vehicles is basically the same except the rear propeller shaft is attached to the transfer case extension instead of the output yoke. Refer to the vehicle data plate before ordering replacement parts. 1. Remove drainplug (7) from transfer case (1). Allow to drain, and install drainplug (7). Tighten drainplug (7) to 35 lb-ft (47 N m). 2. Remove four nuts (2), lockwashers (3), two U-bolts (5), and rear propeller shaft (6) from transfer case yoke (4) and disconnect shaft (6) from yoke (4). Discard lockwashers (3). 3. Disconnect 90°speedometer cable adapter (10) from transfer case (1) and remove speedometer cable (11) from bracket (12). 4. Remove capscrews (8) and disconnect vent line (9) from transfer case (1). 5. Remove four capscrews (18), two straps (17), and front propeller shaft (16) from transfer case yoke (15). 6. Loosen two hose clamps (14) and disconnect rubber cooling lines (13) from transfer case (1). 8-2