TM-9-2320-361-34

2-1/2-TON, 6x6, M44A2 SERIES TRUCKS (MULTIFUEL)

TECHNICAL MANUAL; DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE

MAY 1992
TM-9-2320-361-34

  TM-9-2320-361-34 - Page 35 of 764

TM9-2320-361-34
Table 2-1. Mechanical Troubleshooting (Contd).
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
31. TRANSMISSION GRINDS AND/OR POPS OUT OF GEAR DURING SHIFTING
Remove transmission top cover exposing shift forks and synchronizers (para. 8-3).
a. If any shift fork position is incorrect, adjust (TM 9-2520-246-34-1).
b. If synchronizers are damaged or defective, replace (para. 8-2) and repair (TM 9-2520-
246-34-1) transmission.
END OF TESTING!
TRANSFER CASE
32.
TRANSFER CASE WILL NOT OPERATE FRONT DIFFERENTIAL
Step 1. Check sprag air cylinder operation (TM 9-2520-246-34-1) and test using outside air source
with engine stopped.
If sprag air cylinder operation is defective, replace sprag cylinder (para. 9-2).
Step 2. With air tanks full and engine off, loosen air lines at sprag air cylinder and listen for sprag
clutch engagement in transfer sprag unit.
a. If forward and reverse sprag engagements are not heard, replace transfer sprag air
cylinder (para. 9-3).
b. If sprag engagement is heard, repair sprag unit in transfer case (TM 9-2520-246-34-1).
END OF TESTING!
33. TRANSFER CASE WILL NOT OPERATE REAR DIFFERENTIAL
Step 1. Confirm transmission-to-transfer propeller shafi turns.
a. Proceed to step 2 if transmission-to-transfer propeller shaft can be turned with
transmission and transfer assembly in neutral.
b. If transmission-to-transfer propeller shaft will not turn with transmission and transfer
assembly in neutral. Repair or replace transfer case (para. 9-2).
Step 2. Confirm transfer-to-forward rear axle propeller shaft can be turned. Place transfer shifter
into neutral and raise both rear wheels on one side of vehicle (TM 9-2320-361-20).
a. Remove and repair transfer assembly if propeller shaft turns (para. 9-2).
b. If rear axle propeller shaft will not turn, proceed to differential and rear axle
mechanical troubleshooting sections of TM 9-2320-361-20. If propeller and axles turn
freely replace transfer case (para. 9-2).
END OF TESTING!
34. TRANSFER CASE LEAKS OIL
Check and verify approximate location of oil leak(s).
a. If transfer case front output shaft cover gasket is leaking, remove transfer case and
replace gasket (para. 9-2).
b. If transfer case housing gasket is leaking, remove transfer case and replace gasket
(para. 9-2).
c. If transfer case input flange oil seal is leaking, replace seal (TM 9-2520-246-34-1).
d. If transfer case front output flange oil seal is leaking, replace seal
(TM 9-2520-246-34-1).
e. If transfer case input shaft bearing cover gasket is leaking, replace gasket (TM 9-2520-
246-34-1).
f. If transfer case rear output bearing cover gasket is leaking, replace gasket (TM 9-2520-
246-34-1).
2-20


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