TM9-2320-361-34 Table 2-1. Mechanical Troubleshooting (Contd). MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 35. 36. 37. 38. 39. TRANSFER Step 1 Step 2. TRANSFER g. h. i. j. k. l. If countershaft rear bearing cover gasket is leaking, remove transfer case and replace gasket (para. 9-2 and TM 9-2520-246-34-1). If rear output shaft oil seal is leaking, remove transfer case (para. 9-2) and replace seal (TM 9-2520-246-34-1). If rear output shaft bearing retainer gasket is leaking, remove transfer case (para. 9-2) and replace gasket (TM 9-2520-246-34-1). If top cover gasket is leaking, replace (TM 9-2520-246-34-1). If PTO is leaking oil, repair (malfunction 47). If transfer case oil leak(s) continues, remove transfer case (para. 9-2) and disassemble (TM 9-2520-246-34-1). Check transfer housing halves for defects. Replace defective components (TM 9-2520-246-34-1). . END OF TESTING! CASE NOISY Drain transfer case fluid (LO 9-2320-209-12-1) and check for signs of broken gears, metal shavings, and contamination. If broken gears, metal shavings, or contamination are found in transfer case or on magnetic drain plug, repair or replace transfer case (para 9-2). Check transfer case operation in high and low range and in neutral. If transfer case is defective, repair or replace (para. 9-2). END OF TESTING! CASE GRINDS OR POPS OUT OF GEAR DURING NORMAL VEHICLE OPERATION Replace and repair transfer case (para. 9-2). END OF TESTING! DIFFERENTIAL DIFFERENTIAL NOISY Step 1. Check transfer case operation and noise (malfunction 35). Step 2. Check differential operation. Remove differential drive propeller shaft(s) (TM 9-2320- 361-20). Raise wheels (TM 9-2320-361-20) and manually turn wheels and observe differential operation. If tires still will not rotate, remove differential assembly and replace and repair (para. 10-3 or 10-4). END OF TESTING! DIFFERENTIAL CLUNKS DURING TURNS OR INITIAL TAKEOFF Check differential internal operation. Remove differential and disassemble (para. 10-3 or 10-4). Replace and repair defective components (para. 10-3 or 10-4). END OF TESTING! DIFFERENTIAL LEAKS OIL Step 1. Check differential shafts seals condition. Inspect for presence of gear oil at gaskets and companion flange areas. a. If oil is present, replace seals and gaskets (para. 10-5). b. If repeated seal replacements does not correct problem and leak continues, remove differential (para. 10-3) and repair (para. 10-4). 2-21