Transfer Case Replacement
TM 9-2320-363-34-1 · Chapter 3 — Power Package Maintenance
This task covers: a. Removal b. Cleaning c. Inspection d. Installation
INITIAL SETUP
Applicable Configuration: Equipment Description (Cont):
All except M915A2 Reference Condition Description
Tools and Special Equipment: TM 9-2320-363-10 Wheels Chocked
Shop Equipment, SC 4910-95-CL-A31 TM 9-2320-363-20 Air System Drained
Tool Kit, SC 5180-90-CL-N05
TM 9-2320-363-20 Batteries Disconnected
Materials/Parts:
TM 9-2320-363-20 Transfer Case Oil Drained
Pin, Cotter Clevis P/N 49044-2
General Safety Instructions:
Washer, Lock (2)
References: WARNING
Transfer case weighs 850 lb (386 kg). Support
TM 9-2320-363-10 transfer case with suitable floor jack during
TM 9-2320-363-20 removal or installation to prevent possible injury
to personnel.
Equipment Description:
Reference Condition Description
TM 9-2320-363-10 Transfer Case Shift Lever
Set to Neutral
TM 9-2320-363-10 Spare Tire Removed
TM 9-2320-363-20 Transfer Case to Front
Axle, Transmission to
Transfer Case, and
Transfer Case to
Forward-Rear Axle
Drivelines Removed
REMOVAL
M917A1 and M917A1w/MCS
1. REMOVE NUT (1) AND TWO WASHERS (2) AND DISCONNECT CABLE (3) FROM TEMPERATURE SENSOR (4).
2. REMOVE TWO SCREWS (5) AND DISCONNECT TWO CABLES (6) FROM ALL WHEEL DRIVE SENDING UNIT (7).
3. ON M916A1, DISCONNECT SPEEDOMETER CABLE CONNECTOR (8) FROM DRIVE FITTING (9). ON ALL EXCEPT M916A1, DISCONNECT SPEEDOMETER SENDING UNIT CONNECTOR (9.1) FROM WIRING HARNESS CONNECTOR (9.2).
4. ON M917A1 AND M917A1 W/MCS, DISCONNECT CTIS WIRING HARNESS CONNECTORS (9.3) FROM SPEED SENSOR CONNECTORS (9.4). IF A NEW TRANSFER CASE IS TO BE INSTALLED, REMOVE SPEED SENSOR (9.5) AND INSTALL ON NEW TRANSFER CASE.
5. REMOVE SEVEN FASTENERS (10), CLAMP (11), AND DUST COVER (12).
6. REMOVE COTTER PIN (13) AND PIN (14) AND DISCONNECT CLEVIS (15). DISCARD COTTER PIN.
7. REMOVE TWO CAPSCREWS (16) AND TWO LOCK WASHERS (17) AND SET BRACKET (18) ASIDE. DISCARD LOCK WASHERS.
Tag air lines prior to removal to aid in installation.
8. DISCONNECT TWO AIR LINES (19) FROM SHIFT CHAMBER (20).
9. REMOVE BOLT (21) AND WASHER (22) AND SET BRACKET (23) ASIDE.
10. ATTACH SUITABLE HOIST TO TRANSFER CASE (24) AND REMOVE TWO CAPSCREWS (25) TWO WASHERS (26), AND SHAFT COVER (27).
11. REMOVE 12 CAPSCREWS (28) AND 12 WASHERS (29) AND LOWER TRANSFER CASE (24) TO GROUND.
CLEANING
Use general cleaning methods to clean all parts (page 2-30).
Inspect all parts for wear or damage
1. ATTACH SUITABLE FLOOR JACK TO TRANSFER CASE (1) AND RAISE TRANSFER CASE (1) INTO POSITION.
2. INSTALL 12 WASHERS (2) AND 12 CAPSCREWS (3).
3. INSTALL SHAFT COVER (4) TWO WASHERS (5) AND TWO CAPSCREWS (6).
4. POSITION BRACKET (7) AND INSTALL WASHER (8) AND BOLT (9).
5. CONNECT TWO AIR LINES (10) TO SHIFT CHAMBER (11).
6. POSITION BRACKET (12) AND INSTALL TWO NEW LOCK WASHERS (13) AND TWO CAPSCREWS (14).
7. CONNECT CLEVIS (15) AND INSTALL PIN (16) AND NEW COTTER PIN (17).
8. INSTALL DUST COVER (18), CLAMP (19) AND SEVEN FASTENERS (20).
M917A1 AND M917A1 w/MCS
9. ON M916A1, CONNECT SPEEDOMETER CABLE CONNECTOR (21) TO DRIVE FITTING (22). ON ALL EXCEPT M916A1, CONNECT SPEEDOMETER SENDING UNIT CONNECTOR (22.1) TO WIRING HARNESS CONNECTOR (22.2).
10. ON M917A1 AND M917A1 W/MCS, CONNECT CTIS WIRING HARNESS CONNECTORS (22.3) TO SPEED SENSOR CONNECTORS (22.4).
11. CONNECT TWO CABLES (23) TO ALL WHEEL DRIVE SENDING UNIT (24) AND INSTALL TWO SCREWS (25).
12. CONNECT CABLE (26) TO TEMPERATURE SENSOR (27) AND INSTALL TWO WASHERS (28) AND NUT (29).
Fill transfer case with oil (TM 9-2320-363-20). Install drivelines (TM 9-2320-363-20) Install spare tire (TM 9-2320-363-10). Connect batteries (TM 9-2320-363-20).