TM-9-2320-280-34 HMMWV Direct Support & General Support Maintenance Manual Download
Page 982 of 1258
TM 9-2320-280-34 18-4. TRANSFER CASE REPAIR (MODEL 242) (Cont’d) 15. Inspect range shift fork (16) for burrs, bends, and breaks. Remove burrs. Replace pads (6) if there is any wear. Replace range shift fork (16) if broken, cracked, loose pin (15) or damaged. 16. Inspect range clutch sleeve (17) and mode shift sleeve (7) for burrs, cracks, breaks, and damaged splines or gear teeth. Remove minor burrs. Replace range clutch sleeve (17) or mode shift sleeve (7) if damaged. 17. Inspect mode shift fork assembly (8) for cracks, breaks, bent brackets (2) and (14), and broken or deformed springs (4) and (10). If pads (6) are worn, replace pads (6). Replace bracket (14) if pin (1) is damaged. Mode shift fork assembly (8) must slide freely on shift rail (18) without excessive side free play. Inspect two bushings (5) for damage. Replace bushings (5) if damaged. If free play is excessive, replace mode shift fork assembly (8). Disassemble mode shift fork assembly (8) as follows: (a) Position mode shift fork assembly (8) in vise with bracket (14) secured in vise. NOTE Mode shift fork assembly is under spring tension. Use care when compressing fork to release bracket. (b) Press mode shift fork (8) down and tilt to free and remove mode shift fork assembly (8) from bracket (14). (c) Remove bushing (11), spring (10), and thrust washer (9) from mode shift fork (8). (d) Remove bracket (2), cup (3), and spring (4) from mode shift fork (8). (e) Remove bracket (14) from vise. Assemble mode shift fork assembly (8) as follows: (a) Install bracket (14) in vise. (b) Install spring (4), cup (3), and bracket (2) on short end of mode shift fork (8). Ensure open end of bracket (2) is positioned under mode shift fork lip (12). (c) Install thrust washer (9), spring (10), and bushing (11) on mode shift fork (8). (d) Position mode shift fork assembly (8) on bracket (14). (e) Press mode shift fork (8) down and forward until tab (13) on bracket (2) is seated in bracket (14). (f) Remove mode shift fork assembly (8) from vise. 18. Inspect shift rail (18) for bends, cracks, and grooving. Replace shift rail (18) if damaged. 19. Inspect detent assembly for broken or kinked spring (20), broken or burred poppet (19), or damaged plug (22). Replace poppet spring seal (21) on plug (22). Replace plug (22), spring (20), or poppet (19) if damaged. 18-42