TM 5-3810-294-34
a. Remove drain plug (63) and drain the
(3) Remove bearings (59 and 53) from shaft (56)
lubricant into a suitable container.
with a suitable puller.
b. Remove breather (14) from cover plate (15).
(4) Pull gears (54 and 58) and spacer (55) from shaft
Remove cover plate (15) by removing capscrews (13),
(56).
and lockwashers (12). Remove gaskets (16), plate (17),
n. Remove output shaft assembly (117-121) from
spring 120), plunger (22), and detent ball (21).
housing (61) and disassemble the shaft as follows:
c. Loosen nut (23) and unscrew shaft (10) from
(1) Loosen setscrew (123) and remove driving clutch
shift fork (18) with a suitable tool. Remove the shift fork.
(105).
d. Remove companion flange (3) by removing
(2) Remove bearings (117 and 121) from shaft (119)
cotter pin (1) and nut (2). Remove yokes (77 and 109)
with a suitable puller.
by removing cotter pins (75 and 110) and nuts (76 and
(3) Pull gear (118) from shaft (119) with a suitable
111).
Do not remove yoke deflectors unless
puller.
replacement is necessary.
(4) Do not remove bushing (120) unless replacement
e. Remove nuts (98) and washers (99), and
is necessary.
remove declutch housing (92) from housing (61).
o. Remove bearing cup (122) from housing (61)
Remove gasket (100).
lower bore with a suitable puller.
f. Remove plug (97). Move declutching shaft
p. Remove capscrews (5) and lockwashers (6), and
(86) to the disengaged position, and remove set-screw
remove bearing cage (8) and gasket (9). Press bearing cup
(103). Remove shaft (86) and seal (88).
(25) and oil seal (7) out of the bearing cage.
g. Remove nuts (81) and lockwashers (82).
q. Remove capscrews (70) and lockwashers (69 1,
Remove bearing cage (84). Press bearings (80) and
and remove bearing cap (71) and gasket (68). Remove
891, bearing cups 183 and 87) spacer (85), and oil seal
bearing cup (60) from bearing cap (71) with a suitable puller.
(79) out of bearing cage (84).
15-10. Cleaning, Inspection, and Repair
h. Remove shaft (101) from declutch housing
a. Clean all parts with an approved cleaning solvent
(92). Then remove sliding clutch (102) and shift fork
and dry thoroughly.
(104) from the declutch housing.
b. Inspect all bearings, cups and cones, including
i. Drive dowels (62) out with a suitable punch.
those not removed from parts of the drive unit, and replace if
Remove nuts (46) and lockwashers (48), and remove
roller or cups are worn, pitted or damaged in any way.
cover (50) and gasket'(51).
Remove parts needing replacement with a suitable puller or
j. Remove capscrews (40) and lockwashers
in a press with sleeves. Do not use drifts and hammers
(41). Remove bearing cap (42) and shim (43). Remove
because they mutilate or distort component parts. Replace
bearing cup (52) from the bearing cap with a suitable
defective bearings and bearing cups.
puller.
c. Inspect spur gears and clutches for wear or
k. Remove nuts (37 and 108) and lockwashers
damage. Gear which are scored, pitted, ridged or worn must
(38 and 107). Remove bearing cages (36 and 114) and
be replaced.
shims (35 and 115). Press bearing cup (116) and oil
d. If oil seals and gaskets are removed during
seal (113) out of bearing cage (114). Remove bearing
disassembly, replace with new parts at reassembly.
cup (34) with a suitable puller.
e. Remove nicks, mars, and burrs from machined or
l. Remove main shaft assembly (26-33) from
ground surfaces. Threads must be clean and free to obtain
housing (61). Disassemble the main shaft as follows.
accurate adjustments and correct torque. A fine mill file or
(1) Remove bearing cones (26 and 33) from
India stone is suitable for this purpose. Studs must be tight
input shaft (27) with a suitable puller.
prior to reassembly.
(2) Remove spacer (32).
f. When assembling component parts use a press
(3) Remove gears (28 and 31) from input shaft
where possible.
(27).
15-11. Reassembly
(4) Remove bearings (29) from gear (31) with a
Refer to figure 15-2 and assemble the transfer case as
suitable puller, and then remove spacer (30).
described below. Tighten nuts and capscrews indicated in
m. Remove bushing (74) and speedometer
the figure to the torque specified in table 1-1.
drive
a. Press bearing (25) and oil seal (7) into bearing
gear (73) from bearing cap (71). Remove intermediate
cage (8). Install the bearing cage assembly
shaft assembly (53-59) from housing (61) and
disassemble the shaft as follows:
(1) Cut lockwire (44), and remove capscrews
(45) and bearing retainer (47).
(2) Remove snap ring (67), speedometer drive
gear (66), snap ring (65), and key (57).
15-5
