TM-9-2320-280-34
TRUCK, UTILITY: M998 SERIES
TECHNICAL MANUAL; DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE
JANUARY 1996
TM-9-2320-280-34 - Page 492 of 1258
TM 9-2320-280-34
8 - 3.
TRANSFER CASE REPLACEMENT
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
Six locknuts (Appendix E, Item 58)
General Safety Instructions
Four lockwashers (Appendix E, Item 82)
* Allow transfer case to cool before performing
Cotter pin (Appendix E, Item 8)
this task.
Anaerobic gasket sealer
* Transfer case must be supported during removal
(Appendix B, Item 45)
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.
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 ° 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).
8-2
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