Top Cover and Shelter Shaft.

TM 9-2520-246-34

Figure 4-12. Bearing Covers and Case Plug.

safety wire from the fork setscrew. Remove the

Remove the 18 capscrews, nuts, and lockwashers

setscrew, then remove the shifter shaft from the fork

securing the case cover to the case. (See fig. 4-9.)

assembly. Check the breather assembly. Remove and

Install puller screws in the two puller screw holes

clean or replace it, as necessary.

located in the flange of the case cover. If necessary,

tap on the end of the input shaft and the end of the

m. Countershaft Rear Bearing Cover.

shifter shaft with a mallet. Lift the cover assembly

from the case. Remove and discard the gasket.

NOTE

Remove the inner thrust washer from the input shaft.

Remove the shifter shaft seal.

During assembly, tighten countershaft rear

bearing capscrews to 60-77 lb-ft torque.

k. Rear Output Shaft Assembly. With the case

Use shims to obtain 0.002- to 0.005-inch

cover removed, lift the rear output shaft assembly

end play. The shims are provided as a set.

from the transfer case. (See fig. 4-10.)

The part number for the set is 7521437; the

part numbers for shim sizes are:

l. Top Cover and Shelter Shaft.

Thickness

Ordnance No.

NOTE

.003 .0005

7521441

During assembly, use new gasket and

.005 .0005

7521446

install new safety wire. Tighten setscrew to

.010 .001

7521447

90-118 lb-ft torque.

Remove the four capscrews and

Remove the four capscrews and lockwashers

lockwashers securing the countershaft rear

securing top cover to the transfer case. (See fig. 4-11.)

bearing cover to the transfer case. (See fig.

Remove the top cover and top cover gasket. Discard

4-12.) Remove cover and rear bearing

the gasket. Remove the shifter shaft spring, plunger,

shims.

and ball. Using a pair of wire cutters, remove the

4-6