This task covers:
General mechanic's tool kit:
Muffler removed (TM 9-2320-280-20).
General Safety Instructions
Allow transfer case to cool before
performing this task.
Transfer case must be supported during
removal and installation.
Allow transfer case to cool before performing this task. Failure to
do this may cause injury.
Cover or plug all open lines and connections immediately after
disconnection to prevent contamination. Remove all plugs prior to
Transfer case replacement procedure for the M1097, "A1" and "A2"
vehicles is basically the same except the rear propeller shaft is
attached to the transfer case extension instead of the output yoke.
Refer to the vehicle data plate before ordering replacement parts.
Have drainage container ready to catch fluid.
Remove drainplug (7) from transfer case (1). Allow to drain, and install drainplug (7). Tighten
drainplug (7) to 35 lb-ft (47 N.m).
case yoke (4) and disconnect shaft (6) from yoke (4). Discard lockwashers (3).
Disconnect 90 degree speedometer cable adapter (10) from transfer case (1) and remove
speedometer cable (11) from bracket (12).
Remove capscrews (8) and disconnect vent line (9) from transfer case (1).
Remove four capscrews (18), two straps (17), and front propeller shaft (16) from transfer case
Loosen two hose clamps (14) and disconnect rubber cooling lines (13) from transfer case (1).