NMWR 9-2520-584 model 242 11Feb13.pdf

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING

NATIONAL MAINTENANCE OVERHAUL STANDARDS

FOR

HMMWV TRANSFER CASE

(MODEL 242)

(NSN 2520-01-452-8365)

(NSN 2520-01-469-9893)

This publication is not available through the St. Louis Media Distribution Division. This publication is available through U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/ TECH PUBS, 6501 E. 11 Mile Rd., Warren, MI 48397-5000.

*This manual supersedes NMWR 9-2520-584, dated 28 February 2007, including all changes.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

U.S. ARMY TACOM LIFE CYCLE MANAGEMENT COMMAND

11 FEBRUARY 2013

*NMWR 9-2520-584

WARNING SUMMARY

This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to comply may result in serious injury or death to personnel. Refer to FM 4–25.11 for first aid instructions.

• Improper cleaning methods and use of unauthorized cleaning solutions may result in injury to personnel or damage to equipment. See TM 9-247 for correct information.

• Cleaning compound solvent MIL-PRF-680 is flammable and must not be used near an open flame. A fire extinguisher must be kept nearby when cleaning solvent is used. Use only in well-ventilated areas. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Cleaning compound solvent MIL-PRF-680 is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. Always use protective goggles or face shield and avoid repeated and prolonged skin contact by wearing rubber or solvent resistant gloves. If contact with eyes occurs, flush eyes with water and seek medical attention. Wash hands and skin immediately after exposure with soap and water and use a lanolin-based skin cream to prevent skin drying. Remove contaminated clothing and store, handle, and dispose of contaminated cloths and clothing according to local procedures and plans. Failure to comply may result in damage to environment and health of personnel. Seek medical attention in the event of an injury.

• Ensure cleaning solvent container is sealed when not in use. Store, handle, and dispose of unused and spent solvents in accordance with local procedures and plans. Failure to comply may result in damage to environment and health of personnel. Seek medical attention in the event of an injury.

• Appropriate eye protection must be worn when cleaning with a wire brush, sandblast, grit blast, or other effective methods. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Paints, cleaning solvents, and primers may cause burns, skin irritation, and emit harmful vapors. Inhalation may cause irritation to upper respiratory passages. Keep paints, cleaning solvents, and primers away from fire or heat sources and use only in well-ventilated areas. Keep paints, cleaning solvents, and primers closed when not in use. Always wear protective equipment such as goggles, face mask, gloves, and a proper respirator. If paints, cleaning solvents, and primers contact skin, wash immediately with soap and water. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Prolonged contact with lubricating oil may cause a skin rash. Skin and clothing that come in contact with lubricating oil should be thoroughly washed. Saturated clothing should be removed immediately. Areas in which lubricating oil is used should be well ventilated to keep fumes to a minimum. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Leaking or spilled oil or GAA may cause a slip and fall hazard. Clean any leaking or spilled oil or GAA immediately, using suitable fluid absorbent materials. Dispose of contaminated cloths, rags, or cleaning materials in accordance with local procedures and plans. Failure to comply may result in injury to personnel.

Seek medical attention in the event of an injury.

• Transfer case weighs 96 lbs (43 kg). Ensure suitable lifting device is used prior to removal or installation of transfer case. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.).

NMWR 9-2520-584

a/b blank

LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: This manual supersedes NMWR 9-2520-584, 28 February 2007, including all changes. Zero in the “Change No.” column indicates an original page or work package.″

Date of issue for the original NMWR is:

Original: 11 February 2013

TOTAL NUMBER OF PAGES OF FRONT AND REAR MATTER IS 22 AND

TOTAL NUMBER OF WORK PACKAGES IS 25,

CONSISTING OF THE FOLLOWING:

Page/WP No. Change No.

Front cover Warning Summary (2 pgs) i – iv (4 pgs) Chapter 1 title page (2 pgs) WP 0001 (4 pgs) WP 0002 (2 pgs) Chapter 2 title page (2 pgs) WP 0003 (6 pgs) WP 0004 (12 pgs) WP 0005 (20 pgs) WP 0006 (10 pgs) WP 0007 (2 pgs) WP 0008 (2 pgs) WP 0009 (6 pgs) WP 0010 (2 pgs) WP 0011 (2 pgs) WP 0012 (4 pgs)

Page/WP No. Change No.

WP 0013 (8 pgs) Chapter 3 title page (2 pgs) WP 0014 (8 pgs) WP 0015 (4 pgs) WP 0016 (4 pgs) WP 0017 (6 pgs) WP 0018 (4 pgs) WP 0019 (4 pgs) WP 0020 (2 pgs) WP 0021 (2 pgs) Chapter 4 title page (2 pgs) WP 0022 (2 pgs) WP 0023 (2 pgs) WP 0024 (2 pgs) WP 0025 (2 pgs) Back cover

A/B blank

U.S. ARMY TACOM LIFE CYCLE

MANGEMENT COMMAND

11 FEBRUARY 2013

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING

NATIONAL MAINTENANCE OVERHAUL STANDARDS

FOR

HMMWV TRANSFER CASE

(MODEL 242)

(NSN 2520-01-452-8365)

(NSN 2520-01-469-9893)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and blank forms) through the Internet, on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and better manage the DA Form 2028 program. You may also mail, email, or fax your comments or DA Form 2028 directly to the Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/TECH PUBS, MS 727,6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or commercial (586) 282-1856. A reply will be furnished to you.

This publication is not available through the St. Louis Media Distribution Division. This publication is available through U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/TECH PUBS, 6501 E. 11 Mile Rd., Warren, MI 48397-5000.

*This manual supersedes NMWR 9-2520-584, dated, 28 February 2007, including all changes.

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

*NMWR 9-2520-584

i

TABLE OF CONTENTS

WP Sequence No./Page No.

Chapter 1 - General Information and Equipment Description and Data

General Information ......................................................................................................................... WP 0001

Equipment Description and Data .................................................................................................... WP 0002

Figure 1. Transfer Case. .............................................................................................................. WP 0002-1

Table 1. Transfer Case. ............................................................................................................... WP 0002-1

Chapter 2 - Maintenance Instructions

General Maintenance Instructions ................................................................................................... WP 0003

Table 1. Cleaning Guidelines. ..................................................................................................... WP 0003-3

Table 2. General Inspection Guidelines. .................................................................................... WP 0003-3

Table 3. Repairable Defects. ....................................................................................................... WP 0003-5

Disassembly ..................................................................................................................................... WP 0004

Figure 1. Rear Retainer. .............................................................................................................. WP 0004-2

Figure 2. Transfer Case. .............................................................................................................. WP 0004-3

Figure 3. Mainshaft. .................................................................................................................... WP 0004-4

Figure 4. Rear Half-Case. ........................................................................................................... WP 0004-4

Figure 5. Half-Case. .................................................................................................................... WP 0004-5

Figure 6. Oil Pump. ..................................................................................................................... WP 0004-6

Figure 7. Front Half-Case. .......................................................................................................... WP 0004-6

Figure 8. Front Output Shaft. ..................................................................................................... WP 0004-7

Figure 9. Range Shift Lever Removal. ....................................................................................... WP 0004-7

Figure 10. Front Half-Case. ........................................................................................................ WP 0004-8

Figure 11. Shift Fork Assembly. ................................................................................................ WP 0004-9

Figure 12. Mainshaft. .................................................................................................................. WP 0004-9

Figure 13. Mainshaft. .................................................................................................................. WP 0004-10

Figure 14. Shift Fork. .................................................................................................................. WP 0004-10

Figure 15. Bearing Retainer. ....................................................................................................... WP 0004-11

Figure 16. Low Range Gear. ...................................................................................................... WP 0004-11

Cleaning, Inspection and Repair ..................................................................................................... WP 0005

Figure 1. Front Half-Case. .......................................................................................................... WP 0005-3

Figure 2. Rear Half-Case. ........................................................................................................... WP 0005-4

Figure 3. Differential Disassembly. ............................................................................................ WP 0005-5

Figure 4. Pinion Gears. ............................................................................................................... WP 0005-7

Figure 5. Differential Assembly. ................................................................................................. WP 0005-8

Figure 6. Mainshaft. .................................................................................................................... WP 0005-9

Figure 7. Oil Pump. ..................................................................................................................... WP 0005-10

Figure 8. Rear Retainer. .............................................................................................................. WP 0005-11

Figure 9. Rear Extension. ........................................................................................................... WP 0005-12

Figure 10. Clutchshaft. ................................................................................................................ WP 0005-12

Figure 11. Shift Sector. ............................................................................................................... WP 0005-13

Figure 12. Oil Screen. ................................................................................................................. WP 0005-13

Figure 13. Range Shift Fork. ...................................................................................................... WP 0005-14

Figure 14. Mode Shift Fork. ....................................................................................................... WP 0005-15

Figure 15. Shift Rail. ................................................................................................................... WP 0005-16

Figure 16. Drive Gears. ............................................................................................................... WP 0005-17

Figure 17. Low Range Gear. ...................................................................................................... WP 0005-18 ii

TABLE OF CONTENTS - CONTINUED

Chapter 2 - Maintenance Instructions - Continued

Figure 18. Oil Cooler. ..................................................................................................................WP 0005-19

Assembly .......................................................................................................................................... WP 0006

Figure 1. Low Range Gear. ........................................................................................................ WP 0006-2

Figure 2. Front Half-Case. .......................................................................................................... WP 0006-3

Figure 3. Main Pilot Bearing. ..................................................................................................... WP 0006-3

Figure 4. Shift Sector. ................................................................................................................. WP 0006-4

Figure 5. Range Shift Fork. ........................................................................................................ WP 0006-5

Figure 6. Main Shaft Assembly. ................................................................................................. WP 0006-6

Figure 7. Drive Sprocket. ............................................................................................................ WP 0006-7

Figure 8. Oil Pump. ..................................................................................................................... WP 0006-8

Figure 9. Rear Half-Case. ........................................................................................................... WP 0006-9

Figure 10. Speedometer. ............................................................................................................. WP 0006-10

Transfer Case Testing ...................................................................................................................... WP 0007

Table 1. After Repair Transfer Case Performance Specification. ............................................. WP 0007-1

Preservation, Packaging, and Marking ............................................................................................ WP 0008

Preparation for Storage or Shipment .............................................................................................. WP 0009

Figure 1. Lubrication. .................................................................................................................. WP 0009-3

Figure 2. Placing Transfer Case in Container. ........................................................................... WP 0009-5

Table 1. Final Inspection Report (FIR). ..................................................................................... WP 0009-6

Quality Assurance Requirements .................................................................................................... WP 0010

Illustrated List of Manufactured Items Introduction ...................................................................... WP 0011

Table 1. Manufactured Items Part Number Table of Contents ................................................. WP 0011-1

Illustrated List of Manufactured Items Transfer Case Assembly Stand ........................................ WP 0012

Figure 1. Transfer Case Assembly Stand. .................................................................................. WP 0012-2

Table 1. Materials. ....................................................................................................................... WP 0012-3

Table 2. Material Block. ............................................................................................................. WP 0012-3

Torque Limits .................................................................................................................................. WP 0013

Figure 1. Measuring Screw Diameter. ........................................................................................ WP 0013-1

Figure 2. Capscrew Head Markings. .......................................................................................... WP 0013-1

Figure 3. Measuring Screw. ........................................................................................................ WP 0013-2

Table 1. Torque Limits for Dry Fasteners. ................................................................................ WP 0013-3

Table 2. Torque Limits for Wet Fasteners. ................................................................................ WP 0013-4

Table 3. Torque Limits for Metric Fasteners. ............................................................................ WP 0013-5

Table 4. Torque Specifications for Transfer Case. .................................................................... WP 0013-7

Chapter 3 - Parts Information

Repair Parts and Special Tools List (RPSTL) Introduction ........................................................... WP 0014

Table 1. SMR Code Explanation. ............................................................................................... WP 0014-1

Table 2. Source Code Explanation. ............................................................................................ WP 0014-2

Table 3. Maintenance Code Explanation. ................................................................................... WP 0014-4

Table 4. Maintenance Code Explanation. ................................................................................... WP 0014-4

Table 5. Recoverability Code Explanation. ................................................................................ WP 0014-5

Transfer Case with Container .......................................................................................................... WP 0015

Figure 1. Transfer Case with Container (Sheet 1 of 2). ............................................................ WP 0015-1 iii

TABLE OF CONTENTS - CONTINUED

Chapter 3 - Parts Information - Continued

Figure 1. Transfer Case with Container (Sheet 2 of 2). .............................................................WP 0015-2

Transfer Case Assembly (Front Half) ............................................................................................. WP 0016

Figure 2. Transfer Case Assembly (Front Half). ....................................................................... WP 0016-2

Transfer Case Assembly (Rear Half) .............................................................................................. WP 0017

Figure 3. Transfer Case Assembly (Rear Half). ........................................................................ WP 0017-2

Transfer Case Oil Cooler Assembly ............................................................................................... WP 0018

Figure 4. Transfer Case Oil Cooler Assembly. .......................................................................... WP 0018-2

Transfer Shift Mechanisms .............................................................................................................. WP 0019

Figure 5. Transfer Shift Mechanisms. ........................................................................................ WP 0019-2

National Stock Number Index ......................................................................................................... WP 0020

Part Number Index .......................................................................................................................... WP 0021

Chapter 4 - Supporting Information

References ........................................................................................................................................ WP 0022

Expendable and Durable Items List. ............................................................................................... WP 0023

Table 1. Expendable and Durable Items List. ............................................................................ WP 0023-2

Tool Identification List .................................................................................................................... WP 0024

Table 1. Tool Identification List. ................................................................................................ WP 0024-2

Mandatory Replacement Parts List ................................................................................................. WP 0025

Table 1. Mandatory Replacement Parts List. ............................................................................. WP 0025-2 iv

CHAPTER 1

GENERAL INFORMATION AND EQUIPMENT

DESCRIPTION AND DATA

FOR

HMMWV TRANSFER CASE

(MODEL 242)

NSN 2520-01-452-8365

NSN 2520-01-469-9893

SUSTAINMENT MAINTENANCE

GENERAL INFORMATION

SCOPE

This NMWR is for use by maintenance technicians at certified repair sites. The instructions in this NMWR apply to the transfer case, model 242, NSN 2520-01-452-8365 or NSN 2520-01-469-9893. In case of conflict with other information, the data contained in this NMWR shall take precedence. The condition of the transfer case after rebuild shall be that utility and performance are returned to a near-zero-time/near-zero-miles or like-new condition.

Tolerances and wear limits established by this NMWR are the minimum acceptable standards. Parts, components, assemblies, or subassemblies not meeting these requirements will be disposed of in accordance with the appropriate directive.

Test requirements stated or referenced in this NMWR are the minimum acceptable standards. Components that are found to be worn or defective beyond the repair limits established by this NMWR shall be disposed of in accordance with current directives.

Before performing any rebuild activity, the maintenance technician shall become familiar with all procedures in this NMWR.

MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual;

DA PAM 738-751, Functional Users Manual for The Army Maintenance Management Systems - Aviation (TAMMS-A); or AR 700-138, Army Logistics Readiness and Sustainability.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your transfer case needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you do not like about your equipment. Let us know why you do not like the design or performance.

All non-Aviation/Missile EIRs and PQDRs must be submitted through the Product Data Reporting and Evaluation Program (PDREP) Web site. The PDREP site is: https://www.pdrep.csd.disa.mil/.

If you do not have Internet access, you may submit your information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368 using email, regular mail, or fax using the addresses/fax numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

We will send you a reply.

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items.

Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking.

Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking.

SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

NMWR 9-2520-584 0001

0001-1

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

Procedures for destruction of Army materiel to prevent enemy use can be found in TM 750-244-6, Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use.

PREPARATION FOR STORAGE OR SHIPMENT

Military preservation, Level A packing and marking shall be accomplished with the specific packaging instructions in WP 0008. Overhauled and inspected components shall be preserved, packed, and marked to preclude damage during transit and storage and to properly identify contents. The repair activity must perform packing, packaging, preservation and marking requirements in accordance with the applicable Special Packaging Instructions (SPI). Packaging information can be found at https://www.ilsc.army.mil/tdps/index.asp by searching for transfer case part number 57K3507 or 57K3505.

LIST OF ABBREVIATIONS/ACRONYMS

Abbreviations and acronyms appearing in this manual are defined in the paragraph from where they first appear, after which only the abbreviation or acronym is used. The following is a quick-reference list of all abbreviations and acronyms and their corresponding word or compound term used in this manual.

CAGEC–Commercial and Government Entity Code

CPC–Corrosion Prevention and Control

ECP–Engineering Change Proposal

EIR–Equipment Improvement Recommendations

FIR–Final Inspection Report

MAC–Maintenance Allocation Chart

MEL–Maintenance Expenditure Limit

HMMWV–High Mobility Multi-Wheeled Vehicle

NMWR–National Maintenance Work Requirement

NSN–National Stock Number

P/N–Part Number

PQDR–Product Quality Deficiency Report

QA–Quality Assurance

QTY–Quantity

RPSTL–Repair Parts and Special Tool List

SMR–Source, Maintenance, and Recoverability

SRA–Specialized Repair Activity

TACOM–Tank-automotive and Armaments Command

TAMMS–The Army Maintenance Management System

UOC–Usable On Code

WP–Work Package

QUALITY OF MATERIAL

Material used for replacement, repair, or modification must meet the requirements of this NMWR. If quality of material requirements are not stated in this NMWR, the material must meet the requirements of the drawings, standards, specifications, or approved engineering change proposals applicable to the subject equipment.

ENGINEERING CHANGE PROPOSALS (ECPs)

Engineering Change Proposals (ECPs) are submitted in accordance with AR 70-1, Army Acquisition Policy, directly to Commander, U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCC-HHM, Mail Stop 420, 6501 E. 11 Mile Road, Warren, Michigan 48397-5000. A reply will be furnished to you.

DEVIATIONS AND EXCEPTIONS

Requests for deviations or exceptions to this NMWR are processed in accordance with ISO 9001 Series standards or equivalent. Deviations and exceptions may include certain parts that are no longer available from suppliers and must be repaired.

0001-2

MOBILIZATION REQUIREMENTS

All rebuild/repair procedures contained within this NMWR are required to return the transfer case, model 242, to a serviceable condition.

COST CONSIDERATIONS

This work requirement shall be the basis for establishing the extent of rebuild while taking into consideration cost factors. A determination shall be made on all subassemblies/assemblies to replace worn or damaged components which are available in supply, if acquisition cost is less than the cost to repair and restore to the NMWR standard. The cost to repair/restore any individual item with an established Maintenance Expenditure Limit (MEL) to the NMWR standard shall not exceed the MEL, unless a waiver has been approved in accordance with AMC-R 750-51. This requirement does not apply to items exempted from MEL in accordance with AMC-R 750-51.

END OF WORK PACKAGE

0001-3/4 blank

EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

Directs engine-to-transmission power to front and rear differentials simultaneously. This condition means the vehicle is always in four-wheel drive. The transfer case allows for selection of three drive ranges and a neutral position.

EQUIPMENT DATA

Refer to table 1 for equipment data.

Table 1. Transfer Case.

Manufacturer New Process Gear

Type 2-speed

Model 242

Oil Type Dexron® VI

EQUIPMENT DATA PLATE

The equipment data plate is displayed on the transfer case and shows the manufacturer, model, and serial number. If the data plate is damaged or illegible, it must be replaced. Transfer pertinent data from the damaged data plate to a new data plate.

REBUILD DATA PLATE

After the transfer case has been rebuilt, tested, and documented to be serviceable, a rebuild data plate is attached on flat surface above or below vent line hole. The rebuild data plate must show, at a minimum, rebuild facility and date of repair.

END OF WORK PACKAGE

Figure 1. Transfer Case.

NMWR 9-2520-584 0002

0002-1/2 blank

CHAPTER 2

MAINTENANCE INSTRUCTIONS

FOR

HMMWV TRANSFER CASE

(MODEL 242)

NSN 2520-01-452-8365

NSN 2520-01-469-9893

GENERAL MAINTENANCE INSTRUCTIONS

INITIAL SETUP:

Materials/Parts

Cleaning compound (WP 0023, Item 4)

Cloth, abrasive (WP 0023, Item 5)

Cloth, cleaning (WP 0023, Item 6)

References

TB 43-0213

NASM 33537

TM 9-214

WP 0013

WP 0014

WP 0024

SCOPE

This WP contains general maintenance information pertaining to disassembly, cleaning, inspection, repair, and assembly of the transfer case components. Detailed information will be found in specific WPs.

Maximum overhaul of parts to like-new condition will be mandatory. Parts, components, assemblies, or subassemblies found to be worn or defective beyond limits established by this NMWR will be disposed of in accordance with appropriate directives and, in the case of commercial contracts, as specified in the contract. In instances where new or rebuilt parts, components, assemblies, or subassemblies are unavailable, items will be reviewed on a case-by-case basis. Tolerances and wear limits set forth herein are the minimum acceptable standards.

PRECAUTIONS

All material-handling equipment shall be adequate to ensure safe working conditions for personnel and efficient processing of items.

Follow all WARNINGS, CAUTIONS, and NOTES included in specific WPs to ensure personnel safety and prevent damage to equipment.

SPECIAL PROCESSES

Special processes and equipment required for overhaul operations, as specified in this NMWR, are defined or referenced at the point of their application. When a special process is required, the overhaul activity (when requested) shall provide evidence of compliance with controlling specifications. Following is a summary of special processes that may be required for this NMWR.

END OF TASK

TOOLS AND EQUIPMENT

Tools and equipment required to overhaul this component can be found in the Tool Identification List, WP 0024.

Torque wrench specifications are given in text, as applicable. Metric equivalents are in parentheses following the U.S. standard measurement. (Example: Tighten mounting bolts to 33–40 lb-ft (45–54 N•m).) Standard capscrew markings and torque specifications are found in Torque Limits, WP 0013. Tolerances, torque values, and adjustments are provided in each WP as necessary.

END OF TASK

NMWR 9-2520-584 0003

0003-1

DISASSEMBLY

Each appropriate WP contains specific instructions for disassembly of the components.

Take care in handling parts during disassembly. Nicks, scratches, or other damage caused by careless handling may cause premature failure of equipment.

Matched, married, or mated items (examples: bearings and races, covers and housings, and some gear sets) should be fastened together or otherwise identified as parts being processed together. If one part fails inspection, both parts must be replaced as a set.

END OF TASK

CLEANING

WARNING

• Cleaning compound solvent MIL-PRF-680 is flammable and must not be used near an open flame. A fire extinguisher must be kept nearby when cleaning solvent is used. Use only in well-ventilated areas. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Cleaning compound solvent MIL-PRF-680 is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. Always use protective goggles or face shield and avoid repeated and prolonged skin contact by wearing rubber or solvent resistant gloves. If contact with eyes occurs, flush eyes with water and seek medical attention. Wash hands and skin immediately after exposure with soap and water and use a lanolin-based skin cream to prevent skin drying. Remove contaminated clothing and store, handle, and dispose of contaminated cloths and clothing according to local procedures and plans. Failure to comply may result in damage to environment and health of personnel. Seek medical attention in the event of an injury.

• Ensure cleaning solvent container is sealed when not in use. Store, handle, and dispose of unused and spent solvents in accordance with local procedures and plans. Failure to comply may result in damage to environment and health of personnel. Seek medical attention in the event of an injury.

• Appropriate eye protection must be worn when cleaning with a wire brush, sandblast, grit blast, or other effective methods. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

• Paints, cleaning solvents, and primers may cause burns, skin irritation, and emit harmful vapors. Inhalation may cause irritation to upper respiratory passages. Keep paints, cleaning solvents, and primers away from fire or heat sources and use only in well-ventilated areas. Keep paints, cleaning solvents, and primers closed when not in use. Always wear protective equipment such as goggles, face mask, gloves, and a proper respirator. If paints, cleaning solvents, and primers contact skin, wash immediately with soap and water. Failure to comply may result in injury to personnel.

Seek medical attention in the event of an injury.

• Prolonged contact with lubricating oil may cause a skin rash. Skin and clothing that come in contact with lubricating oil should be thoroughly washed. Saturated clothing should be removed immediately. Areas in which lubricating oil is used should be well ventilated to keep fumes to a minimum. Failure to comply may result in injury to personnel. Seek medical attention in the event of an injury.

0003-2

CLEANING - CONTINUED

CAUTION

Block all ports and mask machined surfaces of aluminum castings before using the following cleaning procedures. Failure to comply may result in damage to equipment.

Do not separate or intermix matched, married, or mated parts during cleaning operations.

For authorized cleaning materials, refer to TB 43-0213, Corrosion Prevention and Control (CPC) for Tactical Vehicles.

Table 1. Cleaning Guidelines.

NO. # ITEM CLEANING

1 Oil passages Remove all obstructions with compressed air or by working a soft wire back and forth through oil passage and flushing it with cleaning solvent.

2 Castings Clean inner and outer surfaces of castings and all areas subject to grease and oil with cleaning solvent.

3 Nonmetallic parts & hoses

Soap and water

END OF TASK

INSPECTION—ACCEPTANCE AND REJECTION CRITERIA

Throughout this NMWR, measurements are used to confirm serviceability of items after a visual inspection.

Measurements will be performed as required by quality assurance, in-process inspection, overhaul procedures, test report, and Final Inspection Report (FIR). Used components and refinished parts, recovered as products of disassembly, will be examined 100 percent to determine serviceability by contractor. Refer to the maintenance WPs, work directive, or contract for more detail. Parts showing evidence of overheating are unrepairable by any process. Discard these parts.

Table 2. General Inspection Guidelines.

INSPECT ACTION

Oil passages Remove all obstructions with compressed air or by working a soft wire or wire brush back and forth through oil passage.

Threads (internal) Inspect threads for minor irregularities. For damaged thread repair, refer to table 3, Repairable Defects.

Machined surfaces Check for damage that could cause oil leakage or malfunction of the part. Refer to table 3, Repairable Defects.

Gear and spline teeth Check for nicks, burrs, or scoring. If any such conditions are found, refer to table 3, Repairable Defects.

Rotating or lockup inner parts Check for cracked rotating or lockup inner parts. If cracked, these parts must be replaced and no repair attempted.

Capscrews and plugs Inspect capscrews and plugs for damage. Replace capscrews and plugs that are damaged and cannot be repaired. Inspect heads for rounding, cracks, or fractures. Replace capscrews or plugs with damaged heads.

Inspect capscrews and plugs for minor irregularities. For damaged thread repair, refer to table 3, Repairable Defects. If major thread damage is found, replace fastener.

END OF TASK

0003-3

REPAIR OR REPLACEMENT

Parts that are beyond wear limit tolerances, broken, cracked, or otherwise damaged may be considered for repair by special processes by requesting approval from TACOM Equipment Specialists. In requesting approval, the rebuild activity will furnish:

1. Written repair procedure

2. Specifications covering the procedure

3. Reference drawing

4. Samples (when requested) of parts repaired by the applicable process

END OF TASK

UNREPAIRABLE DEFECTS

Do not repair any of the following:

1. Casting cracks at through-bores, threaded holes, or high-stress areas

2. Cracked, chipped, ridged, or pitted spline or gear teeth

3. Cracked or split keyways

4. Cracked or chipped snapring grooves

5. Oil channels with cracked walls or chipped edges

6. Pitted or grooved gear teeth and splines, unless otherwise indicated in this NMWR

7. Parts showing evidence of overheating

8. Cracked rotating or lockup inner parts

END OF TASK

0003-4

REPAIRABLE DEFECTS

Table 3. Repairable Defects.

REPAIRABLE PART/AREA REPAIR PROCESS

Machined surfaces Small burrs and scratches may be removed with a fine-mill file or fine-grit abrasive cloth. Discard components that have burrs or scratches too large to repair.

Damaged internal threads Repair threads in tapped holes having minor irregularities by re-tapping with correct size previously used hole tap. Drill out tapped holes having badly damaged threads and install a threaded insert.

Follow kit manufacturer’s and NASM 33537 instructions. When drilling, the land width (space between holes, or between edge of hole and edge of material) must measure no less than three-fourths of the hole diameter. Discard any component with damaged internal threads that are not repairable.

Housing, castings, and shaped, machined surfaces

Unless otherwise indicated, use fine-grit emery cloth, crocus cloth, or soft stone to repair minor nicks, burrs, and scoring. Minor surface irregularities on non-contact surfaces do not need repair. Discard components not repairable.

Gears, splines, and shafts Use crocus cloth, fine-mill file, or soft stone to remove minor nicks, burrs, and scoring. Welding, grinding, machining, plating, etc. of gear or splined teeth to correct defects is not authorized. Discard components not repairable.

Surface rust and corrosion Remove surface rust and corrosion from all internal parts and surfaces.

Mechanical and/or chemical methods may be used. Use fine-grit emery cloth, crocus cloth, or soft stone to remove minor surface rust and corrosion. Do not assemble components having rusted or corroded parts. Corrosion or rust may flake off and cause damage to component while circulating in oil during operation. Discard components not repairable.

END OF TASK

0003-5

ASSEMBLY

CAUTION

Seals may be contaminated with dirt, debris, or moisture when the seal packets are opened. Do not open seal packets until seals are ready to be installed. Failure to comply may result in equipment damage.

Cleanliness is essential in all component assembly operations. Dust and dirt, even in minute quantities, are abrasive. Parts must be kept clean.

See individual WPs for specific assembly instructions.

Replace any part that does not pass visual inspection.

Follow WP instructions for coating bearings, bushings, shafts, seals, friction parts, and other contact surfaces with operating oil to ensure lubrication of parts during initial operation after overhaul. For additional information on bearing lubrication and installation, refer to TM 9-214.

Seal handling:

1. Do not open seal packets until ready to install seal. Seals may become contaminated with dust or dirt and some types of seals can absorb moisture, which may cause damage during installation and/or shorten the lifespan of the seals.

2. Ensure lip-type seals are installed so spring-loaded lip faces toward lubricant.

3. Tighten all capscrews, screws, bolts, nuts, and fittings to torque values as specified in maintenance WPs and in torque specifications in WP 0013.

For parts identification, refer to WP 0014.

END OF TASK

END OF WORK PACKAGE

0003-6

INITIAL SETUP:

Tools and Special Tools Slide hammer adapter (WP 0024, Item 1)

Input gear bearing installer (WP 0024, Item 2)

Output shaft front bearing remover/installer (WP 0024, Item 3)

Extension bushing remover (WP 0024, Item 4)

Screw extractor set (WP 0024, Item 5)

General mechanics tool kit: automotive (WP 0024, Item 6)

Driver handle (WP 0024, Item 7)

Driver handle (WP 0024, Item 8)

Seal installer (WP 0024, Item 10)

Seal installer (WP 0024, Item 11)

Tools and Special Tools - Continued

Mainshaft pilot bearing installer

(WP 0024, Item 12)

Arbor press (WP 0024, Item 13)

Bushing remover/installer bearing

(WP 0024, Item 14)

Bearing remover set (WP 0024, Item 15)

Extension housing seal installer

(WP 0024, Item 16)

Input gear seal installer (WP 0024, Item 17)

Bearing tool (WP 0024, Item 18)

Transfer case assembly stand (WP 0011, Item 1)

NMWR 9-2520-584 0004

0004-1

1. Remove capscrew (Figure 1, Item 1), clamp (Figure 2, Item 2), pinion adapter (Figure 1, Item 6), and driven gear (Figure 1, Item 4) from rear retainer (Figure 1, Item 5).

2. Remove O-ring (Figure 1, Item 3) from pinion adapter (Figure 1, Item 6). Discard O-ring (Figure 1, Item 3).

Figure 1. Rear Retainer.

0004-2

DISASSEMBLY - CONTINUED

3. Remove nut (Figure 2, Item 1), front output yoke (Figure 2, Item 5), and lockwasher seal (Figure 2, Item 4) from transfer case (Figure 2, Item 3). Discard lockwasher seal (Figure 2, Item 4).

4. Move shift range lever (Figure 2, Item 2) to rearmost position.

5. Remove three capscrews (Figure 2, Item 6) from rear extension (Figure 2, Item 8) and rear retainer (Figure 2, Item 10).

CAUTION

Do not pry or wedge rear extension from rear retainer. Sealing surfaces may be damaged.

6. Use soft-nosed hammer or mallet on screw hole bosses (Figure 2, Item 9) of rear extension (Figure 2, Item 8) to break sealing bead and remove rear extension (Figure 2, Item 8) from rear retainer (Figure 2, Item 10).

7. Remove rear output shaft seal (Figure 2, Item 7) from rear extension (Figure 2, Item 8). Discard rear output shaft seal (Figure 2, Item 7).

Figure 2. Transfer Case.

0004-3

8. Remove snapring (Figure 3, Item 1) from mainshaft assembly (Figure 3, Item 2).

9. Remove four capscrews (Figure 4, Item 1) from rear retainer (Figure 4, Item 2) and rear half-case (Figure 4, Item 3).

10. Prying on tabs of rear retainer (Figure 4, Item 2), remove rear retainer (Figure 4, Item 2) from rear half-case (Figure 4, Item 3) and mainshaft (Figure 4, Item 4).

11. Remove two snaprings (Figure 4, Items 5 and 7) and speedometer drive gear (Figure 4, Item 6) from mainshaft assembly (Figure 4, Item 4).

Figure 3. Mainshaft.

Figure 4. Rear Half-Case.

0004-4

12. Remove two capscrews (Figure 5, Item 3) and washers (Figure 5, Item 2) from rear half-case (Figure 5, Item 4).

NOTE

Mark positions of long screws for installation.

13. Remove two long screws (Figure 5, Item 1) from front output end of rear half-case (Figure 5, Item 4).

14. Remove seven screws (Figure 5, Item 12) from rear half-case (Figure 5, Item 4).

NOTE

Use slots in half-cases when separating half-cases.

15. Pry and remove rear half-case (Figure 5, Item 4) from front half-case (Figure 5, Item 10). Lay rear half-case (Figure 5, Item 4) on bench with oil pump (Figure 5, Item 9) up.

CAUTION

Mark position of oil pump to rear half-case before removal. Failure to comply will cause damage to equipment.

16. Rotate oil pickup tube (Figure 5, Item 6) and oil screen (Figure 5, Item 7) out of rear half-case (Figure 5, Item 4) and pull pickup tube (Figure 5, Item 6) out of oil pump inlet port (Figure 5, Item 5).

17. Remove oil pump (Figure 5, Item 9) from rear half-case (Figure 5, Item 4).

18. Remove oil screen (Figure 5, Item 7) and pickup tube (Figure 5, Item 6) from hose (Figure 5, Item 8).

19. Remove magnetic pickup (Figure 5, Item 11) from pocket in front half-case (Figure 5, Item 10).

Figure 5. Half-Case.

0004-5

20. Remove oil tube seal (Figure 7, Item 2) from oil pump (Figure 7, Item 1). Discard oil tube seal (Figure 7, Item 2).

21. Remove snapring (Figure 7, Item 1) securing drive sprocket (Figure 7, Item 2) to mainshaft assembly (Figure 7, Item 3).

22. Remove drive sprocket (Figure 7, Item 2) and drive chain (Figure 7, Item 4) from front half-case (Figure 7, Item 5).

Figure 6. Oil Pump.

Figure 7. Front Half-Case.

0004-6

23. Remove front output shaft (Figure 8, Item 2) and driven gear (Figure 8, Item 4) from front half-case (Figure 8, Item 3).

24. Remove snapring (Figure 8, Item 1) and driven gear (Figure 8, Item 4) from front output shaft (Figure 8, Item 2).

25. Remove nut (Figure 9, Item 4), washer (Figure 9, Item 3), and shift lever (Figure 9, Item 2) from sector shaft (Figure 9, Item 1).

26. Remove plug (Figure 9, Item 5) from low range fork access hole (Figure 9, Item 7).

27. Using screw extractor in tapered drive pin (Figure 9, Item 6), turn counterclockwise and withdraw tapered drive pin (Figure 9, Item 6) from low range fork access hole (Figure 9, Item 7). Discard tapered drive pin (Figure 9, Item 6).

Figure 8. Front Output Shaft.

1 2

Figure 9. Range Shift Lever Removal.

0004-7

28. Remove shifter detent plug (Figure 10, Item 10), O-ring (Figure 10, Item 9), spring (Figure 10, Item 8), and poppet (Figure 10, Item 7) from front half-case (Figure 10, Item 4). Discard O-ring (Figure 10, Item 9).

29. Remove two nuts (Figure 10, Item 6), washers (Figure 10, Item 5), and oil cooler (Figure 10, Item 1) from front half-case (Figure 10, Item 4).

30. Remove two O-rings (Figure 10, Item 2) from oil cooler (Figure 10, Item 1). Discard O-rings (Figure 10, Item 2).

Figure 10. Front Half-Case.

0004-8

31. Pull shift rail (Figure 11, Item 5) from mode shift fork assembly (Figure 11, Item 4).

32. Remove mode shift fork assembly (Figure 11, Item 4) and mainshaft assembly (Figure 11, Item 1) from front half-case (Figure 11, Item 3) as a unit.

33. Remove mode shift fork assembly (Figure 11, Item 4) from mode shift sleeve (Figure 11, Item 2) on mainshaft assembly (Figure 11, Item 1).

34. Remove mode shift sleeve (Figure 11, Item 2) from mainshaft assembly (Figure 11, Item 1).

35. Remove snapring (Figure 12, Item 1) and keyed thrust washer (Figure 12, Item 2) from mainshaft (Figure 12, Item 4).

36. Slide intermediate clutch shaft (Figure 12, Item 3) off mainshaft (Figure 12, Item 4).

Figure 11. Shift Fork Assembly.

Figure 12. Mainshaft.

0004-9

37. Remove differential snapring (Figure 13, Item 1) from mainshaft (Figure 13, Item 6).

NOTE

Needle bearings will fall free when differential is removed from mainshaft.

38. Remove differential assembly (Figure 13, Item 2) from mainshaft (Figure 13, Item 2).

39. Remove two thrust washers (Figure 13, Items 3 and 5) and 53 needle bearings (Figure 13, Item 4) from mainshaft (Figure 13, Item 6).

40. Twist range shift fork (Figure 14, Item 2) and range clutch sleeve (Figure 14, Item 4) to disengage pin (Figure 14, Item 1) from shift sector (Figure 14, Item 5) and remove range shift fork (Figure 14, Item 2) and range clutch sleeve (Figure 14, Item 4) from front half-case (Figure 14, Item 3).

41. Remove shift sector (Figure 14, Item 5) from front half-case (Figure 14, Item 3).

Figure 13. Mainshaft.

Figure 14. Shift Fork.

0004-10

42. Remove four screws (Figure 15, Item 2) and bearing retainer (Figure 15, Item 3) from front half-case (Figure 15, Item 5). Pry on bearing retainer (Figure 15, Item 3) at slots (Figure 15, Item 7).

43. Remove input gear seal (Figure 15, Item 1) from bearing retainer (Figure 15, Item 3). Discard input gear seal (Figure 15, Item 1).

44. Remove snapring (Figure 15, Item 4) from input gear shaft (Figure 15, Item 6).

45.…