TM 9-2320-280-34
This task covers:
a. Removal
b. Installation
INITIAL SETUP:
Tools
Manual References
General mechanic's tool kit:
TM 9-2320-280-20
automotive (Appendix G, Item 1)
TM 9-2320-280-24P
Special Tools
Equipment Condition
Torque adapter 9/16 in.
Muffler removed (TM 9-2320-280-20).
(Appendix G, Item 106)
Muffler support bracket removed
(TM 9-2320-280-20).
Materials/Parts
General Safety Instructions
Six locknuts (Appendix E, Item 64)
Allow transfer case to cool before
Four lockwashers (Appendix E, Item 103)
performing this task.
Lock pin (Appendix E, Item 170)
Transfer case must be supported during
Anaerobic gasket sealer (Appendix B, Item 45)
removal and installation.
Personnel Required
Maintenance Level
One mechanic
Direct support
One assistant
a. Removal
WARNING
Allow transfer case to cool before performing this task. Failure to
do this may cause injury.
CAUTION
Cover or plug all open lines and connections immediately after
disconnection to prevent contamination. Remove all plugs prior to
connection.
NOTE
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.
1.
Remove drainplug (7) from transfer case (1). Allow to drain, and install drainplug (7). Tighten
drainplug (7) to 35 lb-ft (47 N.m).
2.
Remove four nuts (2), lockwashers (3), two U-bolts (5), and rear propeller shaft (6) from transfer
case yoke (4) and disconnect shaft (6) from yoke (4). Discard lockwashers (3).
3.
Disconnect 90 degree speedometer cable adapter (10) from transfer case (1) and remove
speedometer cable (11) from bracket (12).
4.
Remove capscrews (8) and disconnect vent line (9) from transfer case (1).
5.
Remove four capscrews (18), two straps (17), and front propeller shaft (16) from transfer case
yoke (15).
6.
Loosen two hose clamps (14) and disconnect rubber cooling lines (13) from transfer case (1).
Change 2
