TM 9-2520-246-34 i. Case Cover. Use care not to during removal items and must damaged. NOTE damage or lose taper pins since they are non-supply be fabricated if lost or (1) Polish the end of the shifter shaft to remove roughness and paint. (See fig. 4-31.) Remove the 18 capscrews, nuts, and lockwashers securing the case cover to the case. Remove the three taper pins from the case and cover, with a drift or punch. NOTE Install taper pins, install new gasket, aline case cover with taper pins, and tighten nut and capscrews evenly and alternately. Tighten capscrews marked Y and W to 60- 77 lb-ft torque. Tighten remaining capscrews marked Z to 67-87 lb-ft torque. (2) Install puller screws in the two puller-screw holes located in the flange of the case cover. (See fig. 4-31.) If necessary, drive on the end of the input shaft and tap on the end of the shifter shaft with a mallet. Lift the cover assembly from the case. Remove and discard the gasket. Remove the outer thrust washer from the input shaft. j. Rear Output Shaft Assembly. After the case cover has been removed, lift the rear output shaft assembly (fig. 4-33) from the transfer case. Figure 4-32. Removal of Front Output Shaft and Reverse Shift Assembly. k. Transfer Top Cover and Shifter Shaft. NOTE When assembling, use a new gasket and install new lockwire. Tighten capscrews and lockwashers to 22-28 lb-ft torque. Remove the four capscrews and lockwashers securing the top cover to the transfer case. (See fig. 4- 33). Remove the top cover and top cover gasket. Discard the gasket. Remove the shifter shaft spring, plunger, and ball. (See fig. 4-34.) Using a pair of wire cutters, remove the lockwire from the fork setscrew. Remove the setscrew, then remove the shifter shaft from the fork assembly. l. Input Shaft Assembly, Fork Assembly, and Idler Shaft Assembly. Using a soft drift pin and hammer, drive the input shaft assembly, fork assembly, and idler shaft assembly from the transfer case. Figure 4-33. Removal of Rear Output, Idler, and Input Shaft Assemblies m. Rear Output Shaft Rear Bearing Cover. NOTE When assembling, tighten rear output shaft rear bearing cover capscrews to 60-77 lb-ft torque. For the installation of shims and rear bearing adjustments, refer to section VII of this chapter. Remove the six capscrews and lockwashers securing the rear output shaft rear bearing cover to the transfer case. (See fig. 4-35.) Remove the bearing cover and shims from the case. Using a suitable tool, remove the oil seal from the rear output shaft cover. 4-23