Direct Support Mechanical Troubleshooting - continued

TM 9-2320-386-24-1-2

0293 00

Direct Support Mechanical Troubleshooting (Contd).

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

If transfer case front output flange oil seal is leaking, replace seal (TM 9-2520-246-34-1).

If transfer case input shaft bearing cover gasket is leaking, replace gasket (TM 9-2520-246-34-1).

If transfer case rear output bearing cover gasket is leaking, replace gasket (TM 9-2520-246-34-1).

If countershaft rear bearing cover gasket is leaking, remove transfer case and replace

gasket (TM 9-2320-361-34 and TM 9-2520-246-34-1).

h. If rear output shaft oil seal is leaking, remove transfer case (TM 9-2320-361-34) and

replace seal (TM 9-2520-246-34-1).

i. If rear output shaft bearing retainer gasket is leaking, remove transfer case (TM 9-2320-

361-34) and replace gasket (TM 9-2520-246-34-1)

j. If top cover gasket is leaking, replace (TM 9-2520-246-34-1).

k. If transfer case oil leak(s) continues, remove transfer case (TM 9-2320-361-34) and

disassemble (TM 9-2520-246-34-1). Check transfer housing halves for defects. Replace

defective components (TM 9-2520-246-34-1).

END OF TESTING!

33. TRANSFER CASE NOISY

Step 1. Drain transfer case fluid (WP 0023 00) and check for signs of broken gears, metal shavings,

and contamination.

If broken gears, metal shavings, or contamination are found in transfer case or on magnetic

drainplug, repair or replace transfer case (TM 9-2320-361-34).

Step 2. Check transfer case operation in HIGH and LOW range and in NEUTRAL.

If transfer case is defective, repair or replace (TM 9-2320-361-34).

END OF TESTING!

34. TRANSFER CASE GRINDS OR POPS OUT OF GEAR DURING NORMAL VEHICLE OPERATION

Replace and repair transfer case (TM 9-2320-361-34).

END OF TESTING!

DIFFERENTIAL

35. DIFFERENTIAL NOISY

Step 1. Check transfer case operation and noise (malfunction 33).

Step 2. Check differential operation. Remove differential drive propeller shaft(s) (WP 0146 00). Raise

wheels (TM 9-2320-386-10) and manually turn wheels and observe differential operation.

If tires still will not rotate, remove differential assembly and replace and repair

(TM 9-2320-361-34).

END OF TESTING!

36. DIFFERENTIAL CLUNKS DURING TURNS OR INITIAL TAKEOFF

Check differential internal operation. Remove differential and disassemble (TM 9-2320-361-34).

Replace and repair defective components (TM 9-2320-361-34).

END OF TESTING!

37. DIFFERENTIAL LEAKS OIL

Step 1. Check differential shafts seals condition. Inspect for presence of gear oil at gaskets and

companion flange areas.

a. If oil is present, replace seals and gaskets (TM 9-2320-361-34).

b. If repeated seal replacement does not correct problem and leak continues, remove

differential (TM 9-2320-361-34).

0293 00-9