Transfer Case Cover.

TM 9-2520-246-34

(2) Remove input shaft rear bearing snapring (fig.

(2) Using a suitable tool, remove the shifter shaft

4-16) from the end of input shaft. Place input shaft

oil seal (fig. 4-17) from cover.

assembly in arbor press with rear bearing and high

range gear up. Install a suitable puller (item 4, table 2-

(3) Remove snapring and press countershaft front

1) around input shaft high range gear. Removal of

bearing cup from the front cover using a suitable

high range gear in this manner will push the gear

remover and replacer. (See fig. 4-18.)

bearings, spacer, thrust washer, and rear bearing from

the input shaft.

(4) Remove snapring and press rear output shaft

bearing cup (fig. 4-17) from the front cover using a

(3) Place the high range gear in an arbor press

suitable remover and replacer.

and press high range gear ball bearings and spacer

from bore of the high range gear. Apply pressure to

the inner race of the bearing only. (See fig. 4-16.)

(4) Slide synchronizer assembly from input shaft.

(See fig. 4-16.)

(5) Place input shaft assembly (fig. 4-16) in arbor

press, low range gear up. Place support bars beneath

the low range gear and press shaft from input shaft

low range gear, gear bearings, spacer, and thrust

washer (if still installed).

(6) Place input shaft low range gear (fig. 4-16) in

a press, and press low range gear bearings and spacer

from input shaft low range gear. Apply pressure to the

inner race of bearing only.

d. Transfer Case Cover.

Figure 4-18. Remover and Replacer with Handle.

NOTE

e. Front Output Shaft Cover.

When installing input shaft front bearing,

apply pressure on the outer race of the

NOTE

bearing only. Also, replace shifter shaft oil

seal.

Coat output shaft and oil seals with a

universal gear lubricant (GO), MIL-L-2105,

(1) Press input shaft front bearing and snapring

before assembling to prevent damage to

(fig. 4-17) from the front cover using suitable remover

seals.

and replacer (item 6, table 2-1).

Remove front output shaft oil seal snapring. (See

fig. 4-19.) To remove seal from cover, place in press

and press against front bearing thrust washer.

f. Transfer Case.

NOTE

When pressing bearing cups back in

transfer case, be sure that bearing cups are

not cocked, because damage to bearing

cups and transfer case might result.

Remove countershaft and rear output shaft

bearing cups from the transfer case, using suitable

remover and replacer (item 6, table 2-1). (See fig, 4-

Figure 4-17. Transfer Case Cover Disassembly.

20.)

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