TM9-2320-361-34 Table 2-1. Mechanical Troubleshooting (Contd). MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 31. TRANSMISSION GRINDS AND/OR POPS OUT OF GEAR DURING SHIFTING Remove transmission top cover exposing shift forks and synchronizers (para. 8-3). a. If any shift fork position is incorrect, adjust (TM 9-2520-246-34-1). b. If synchronizers are damaged or defective, replace (para. 8-2) and repair (TM 9-2520- 246-34-1) transmission. END OF TESTING! TRANSFER CASE 32. TRANSFER CASE WILL NOT OPERATE FRONT DIFFERENTIAL Step 1. Check sprag air cylinder operation (TM 9-2520-246-34-1) and test using outside air source with engine stopped. If sprag air cylinder operation is defective, replace sprag cylinder (para. 9-2). Step 2. With air tanks full and engine off, loosen air lines at sprag air cylinder and listen for sprag clutch engagement in transfer sprag unit. a. If forward and reverse sprag engagements are not heard, replace transfer sprag air cylinder (para. 9-3). b. If sprag engagement is heard, repair sprag unit in transfer case (TM 9-2520-246-34-1). END OF TESTING! 33. TRANSFER CASE WILL NOT OPERATE REAR DIFFERENTIAL Step 1. Confirm transmission-to-transfer propeller shafi turns. a. Proceed to step 2 if transmission-to-transfer propeller shaft can be turned with transmission and transfer assembly in neutral. b. If transmission-to-transfer propeller shaft will not turn with transmission and transfer assembly in neutral. Repair or replace transfer case (para. 9-2). Step 2. Confirm transfer-to-forward rear axle propeller shaft can be turned. Place transfer shifter into neutral and raise both rear wheels on one side of vehicle (TM 9-2320-361-20). a. Remove and repair transfer assembly if propeller shaft turns (para. 9-2). b. If rear axle propeller shaft will not turn, proceed to differential and rear axle mechanical troubleshooting sections of TM 9-2320-361-20. If propeller and axles turn freely replace transfer case (para. 9-2). END OF TESTING! 34. TRANSFER CASE LEAKS OIL Check and verify approximate location of oil leak(s). a. If transfer case front output shaft cover gasket is leaking, remove transfer case and replace gasket (para. 9-2). b. If transfer case housing gasket is leaking, remove transfer case and replace gasket (para. 9-2). c. If transfer case input flange oil seal is leaking, replace seal (TM 9-2520-246-34-1). d. If transfer case front output flange oil seal is leaking, replace seal (TM 9-2520-246-34-1). e. If transfer case input shaft bearing cover gasket is leaking, replace gasket (TM 9-2520- 246-34-1). f. If transfer case rear output bearing cover gasket is leaking, replace gasket (TM 9-2520- 246-34-1). 2-20