TM-9-2320-280-34 HMMWV Direct Support & General Support Maintenance Manual Download
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18-4. TRANSFER CASE REPAIR (Model 242) This task covers: a. Disassembly c. Inspection and Repair b. Cleaning d. Assembly 1. Remove capscrew (1), clamp (2), pinion adapter (6), and driven gear (4) from rear retainer (5). 2. Remove O-ring (3) from pinion adapter (6). Discard O-ring (3). 3. Remove nut (7), front output yoke (8), and lockwasher seal (9) from transfer case (11) Discard lockwasher seal (9). 4. Move shift range lever (10) to most rear position. 5. Remove three capscrews (13) from rear extension (14) and rear retainer (5). CAUTION Do not pry or wedge rear extension from rear retainer. Sealing surfaces could be damaged. 6. Use a soft nosed hammer or mallet on screw hole bosses (15) of rear extension (14) to break sealing bead and remove rear extension (14) from rear retainer (5). 7. Remove rear output shaft seal (12) from rear extension (14). Discard rear output shaft seal (12). a. Disassembly INITIAL SETUP: Tools ____ General mechanic's tool kit: automotive (Appendix G, Item 1) Screw extractor set (Appendix G, Item 78) Arbor press (Appendix G, Item 77) Special Tools __________ Slide hammer adapter (Appendix G, Item 55) Driver handle (Appendix G, Item 34) Input gear seal installer (Appendix G, Item 69) Bearing remover set (Appendix G, Item 73) Input gear bearing installer (Appendix G, Item 61) Output shaft front bearing remover/installer (Appendix G, Item 70) Extension bushing remover (Appendix G, Item 72) Bushing remover/bearing installer (Appendix G, Item 67) Extension housing seal installer (Appendix G, Item 75) Output shaft seal installer (Appendix G, Item 71) Bearing tool (Appendix G, Item 74) Mainshaft pilot bearing installer (Appendix G, Item 68) Seal installer (Appendix G, Item 139) Seal installer (Appendix G, Item 140) Special Tools (Cont’d) _________________ Drive handle (Appendix G, Item 141) Materials/Parts _____________ Pinion adapter O-ring (Appendix E Item 107) Two O-rings (Appendix E, Item 117) Seal, lockwasher (Appendix E, Item 197) Seal, oil tube (Appendix E, Item 195) Poppet spring seal (Appendix E, Item 185) Input gear seal (Appendix E, Item 180) Front output shaft seal (Appendix E, Item 188) Rear output drive seal (Appendix E, Item 194) Pin, tapered drive (Appendix E, Item 124) Bushing (Appendix E, Item 5) Anaerobic gasket sealer (Appendix B, Item 45) Petrolatum (Appendix B, Item 38) Silicone sealant (Appendix B, Item 44) Sealing compound (Appendix B, Item 52) Transmission fluid (Appendix B, Item 23) Transfer case support stand (Appendix C, Fig. 4) Manual References ________________ TM 9-2320-280-24P Equipment Condition _________________ Transfer case removed (para. 8-3). Maintenance Level _______________ General support TM 9-2320-280-34 18-26 Change 1