NMWR_9-2520-584_242_Xfer_feb_2007.pdf

*NMWR 9-2520-584

*Supersedes NMWR 9-2520-584, 30 April 2005

NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING NATIONAL 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 AG publications centers. This publication is available through U.S. Army TACOM, Warren, MI 48397-5000.

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

U.S. ARMY TANK-AUTOMOTIVE AND ARMAMENTS COMMAND

WARREN, MICHIGAN 48397-5000

28 February 2007

M 242 TRANSFER CASE

NMWR 9-2520-584

WARNING SUMMARY

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

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.).

Do not use compressed air to dry bearings. Spinning a dry bearing with compressed air may cause injury to personnel or damage to equipment.

Direct all personnel to stand clear during hoisting operations. Failure to do this may cause injury.

When steam cleaning, protective clothing must be used. Failure to do this may cause injury.

When sanding fiberglass, personal protective equipment (respirator, goggles/shield, gloves, coveralls, etc.) must be used. Failure to do this may cause injury.

Do not operate heater in enclosed areas. Exhaust gases can kill. Make sure work area is well ventilated and exhaust fumes are routed away from test area.

Drycleaning solvent is flammable and will not be used near an open flame. A fire extinguisher will be kept nearby when solvent is used. Use only in well-ventilated places. Failure to do this may result in injury to personnel or damage to equipment.

Protective eye equipment (goggles/shield) must be worn when removing snaprings or springs.

Failure to comply may result in injury to personnel.

a/b blank

LIST OF EFFECTIVE PAGES / WORK PACKAGES

The date of issue for original pages/work pages for this TM is:

Original… 28 February 2007

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 72.

TOTAL NUMBER OF WORK PACKAGES IS 8.

THE PAGES/WORK PACKAGES CONSISTS OF THE FOLLOWING:

Page No. ….................................................Change No.*

Warning a …………………………… Warning b blank………………………………… 0 A………………………………………………… 0 B blank………………………………………….. 0 i………………………………………………… 0 ii blank………………………………………… 0 iii………………………………………………… 0 iv blank …………………………………………. 0

WP 0001 00 – WP 0008 00....………………….. 0

*Zero in this column indicates an original page or work package

A/B blank

National Maintenance Work Requirement *HEADQUARTERS, NATIONAL MAINTENANCE WORK REQUIREMENT

CONTAINING NATIONAL OVERHAUL STANDARDS

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is http://aeps.ria.army.mil. If you need a password, scroll down and click on “ACESS REQUEST FORM.” The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax or E-mail your letter or DA Form 2028 direct to: AMSTA-LC-CI Tech Pubs, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The E-mail address is TACOM-TECH-PUBS@ria.army.mil. The fax number is DSN 793- 0726 or Commercial (309) 782-0726.

*This manual supersedes NMWR 9-2520-584, dated 30 April 2005 i/ii blank

U.S. ARMY TANK-AUTOMOTIVE AND ARMAMENTS COMMAND

WARREN, MI 28 FEBRUARY 2007

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

TABLE OF CONTENTS

Work Package/Page No.

CHAPTER 1 GENERAL INFORMATION & SUPPORTING INFORMATION

GENERAL INFORMATION…………………………………………………… WP 0001 00

SUPPORTING INFORMATION………………………………………………. WP 0002 00

CHAPTER 2 REPAIR

TRANSFER CASE REPAIR (MODEL 242) ………………………………….. WP 0003 00

AFTER REPAIR TRANSFER CASE PERFORMANCE TEST ……………… WP 0004 00

PARTS DISPOSAL AND QUALITY ASSURANCE…………………………. WP 0005 00

SPECIAL PACKAGING INSTRUCTIONS…………………………………… WP 0006 00

MANDATORY REPLACEMENT LIST………………………………………. WP 0007 00

TEST STAND FABRICATION………..………………………………………. WP 0008 00

iii/iv blank

CHAPTER 1

GENERAL INFORMATION & SUPPORTING INFORMATION

0001 00

NATIONAL MAINTENANCE WORK REQUIREMENT (NMWR)

GENERAL INFORMATION

This Work Package (WP) Covers:

Scope; Applicable Documents; Definitions; Transfer Case Repair Description; Maintenance Forms, Records, and Reports; Reporting Equipment Improvement Recommendations (EIR); Corrosion Prevention and Control (CRC); Quality of Material; and Engineering Change Proposals (ECP)

SCOPE

This NMWR covers the repair of the New Process Gear Model 242 Transfer Case, NSN 2520-01-452- 8365, PN 12342643-1, and NSN 2520-01-469-9893, PN 12447125. The transfer case is used in the High Mobility Multipurpose Wheeled Vehicle (HMMWV). The procedures contained in this NMWR describe disassembly, inspection, component repair, and assembly of the Transfer Case. It will provide a transfer case that is serviceable and issuable to all customers without limitation or restriction, Condition Code A.

APPLICABLE DOCUMENTS

You can receive copies of the applicable documents upon request by contacting:

Commodity Business Unit

USA TACOM

AMSTA-LC-CHL

mcinernj@tacom.army.mil Warren MI 48397-5000

The following documents form a part of this NMWR to the extent specified herein.

1. TM 9-2320-280-34

2. TM 9-2320-280-24P

3. TM 9-214

4. MIL-P-14105C

5. TACOM Drawing Number 12342643 or 12447125

6. Packaging Instructions Appendix A

0001 00-1

DEFINITIONS

1. Repair: Restoring a component to its original performance condition, replacing parts if/as necessary.

2. OEM: The original equipment manufacturer. The company that originally manufactured, fabricated, or supplied a transfer case component or part. OEM may include items manufactured by a subcontractor for an original equipment manufacturer, provided that the name or trademark of the OEM is shown on the item, label, or container.

3. After Market Part: Any part or component that has been manufactured or fabricated by a company other than the original equipment manufacturer or their approved subcontractors and sold as a replacement part for an OEM part or component.

4. Serviceable Part: Any part that is capable of meeting or exceeding the minimum OEM standards for performing the function for which it was originally desired.

5. Non-serviceable Part: Any part that no longer meets minimum OEM standards.

TRANSFER CASE REPAIR DESCRIPTION

1. Transfer case assemblies, Model 242, NSN 2520-01-452-8365 or 2520-01-469-9893 will be in various states of disrepair. Determine that component parts conform to established standard(s).

Reject all nonconforming parts. All gear teeth, machine surfaces, shims, and bearing caps will be free from embedded metal chips or metal shavings. You will repair transfer case assemblies so that they meet the configuration of drawing 12342643 or 12447125 and the performance specifications described in WP 0004 00.

2. You can use OEM or equivalent after market repair parts when repairing the transfer case. When using other than OEM parts, the parts used must be able to be repaired or replaced using the existing procedures, tools, and repair parts specified in the HMMWV technical manuals.

3. Repaired transfer case assemblies must maintain the same transfer case to vehicle interface as the original equipment transfer case.

4. Transfers with cracked cases may be repaired, using new cases. See TM 9-2320-280-24P for parts.

5. You may cannibalize serviceable or repairable parts from any unrepairable transfer case assembly for use when repairing other transfer case assemblies.

6. During the course of repair, any sub-components/parts of the transfer case showing obvious signs of imminent failure, excessive wear, or deterioration will be replaced with a fully serviceable replacement.

0001 00-2

MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment will be those prescribed by (as applicable) DA PAM 738-750, Functional Users Manual for the Army Maintenance Management System (TAMMS); DA PAM 738-751, Functional Users Manual for the Army Maintenance Management - Aviation (TAMMS-A); or AR 700-138, Army Logistics Readiness and Sustainability.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your transfer case assembly, model 242, NSN 2520-01-452-8365 or 2520-01-469-9893 needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don't like about your equipment. Let us know why you don't like the design or performance. Put it on an SF 368 (Product Quality Deficiency Report). Mail it to the address specified in DA PAM 738-750, Functional Users Manual for the Army Maintenance Management System (TAMMS), or as specified by the acquiring activity. We will send you a reply.

CORROSION PREVENTION AND CONTROL (CPC)

1. 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.

2. While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem.

3. If a corrosion problem is identified, it can be reported using SF 368, Product Quality Deficiency Report. Use of key words such as "corrosion," "rust," "deterioration," or "cracking" will ensure that the information is identified as a CPC problem.

4. The form should be submitted to the address specified in DA PAM 738-750, Functional Users Manual for the Army Maintenance Management System (TAMMS).

QUALITY OF MATERIAL

Parts and material used for replacement, repair, or modification shall meet the requirements of the equipment drawings and specified if standards are not provided in this NMWR.

ENGINEERING CHANGE PROPOSALS (ECP)

Engineering Change Proposals (ECPs) will be submitted using DD Form 1693 (Engineering Change Proposal [Short Form]). (Refer to MIL-STD-973, Configuration Management, for instructions.)

Completed forms should be mailed directly to Commander, U.S. Army Tank-automotive and Armaments Command, ATTN: AMSTA-LC-TR-E-PDQR, MS 267, Warren, MI 48397-5000.

END OF TASK

0001 00-3

0002 00

SUPPORTING INFORMATION

THIS WORK PACKAGE (WP) COVERS:

Cleaning; General Inspection and General Repair

CLEANING

a. General Instructions. Cleaning procedures will be the same for the majority of parts and components which make up the vehicle subassemblies. General cleaning procedures are detailed in "b" through "h".

b. The Importance of Cleaning. Great care and effort are required in all cleaning operations. The presence of dirt and foreign material is a constant threat to satisfactory vehicle operation and maintenance. The following will apply to all cleaning operations:

1. Hands must be kept free of any accumulation of grease which can collect dust and grit.

2. Clean all parts before inspection, after repair, and before assembly.

3. After cleaning, all parts must be covered or wrapped in plastic or paper to protect them from dust and/or dirt.

c. Disassembled Parts Cleaning. Place all disassembled parts in wire baskets for cleaning.

1. Dry and cover all cleaned parts.

2. Place on or in "racks" and hold for inspection or repair.

3. All parts subject to rusting must be lightly oiled and wrapped.

4. Keep all related parts and components together. Do not mix parts.

0002 00-1

d. Castings.

1. Clean inner and outer surfaces of castings and all areas subject to grease and oil with cleaning solvents. Refer to TM 9-247.

2. Use a stiff brush to remove sludge and gum deposits.

WARNING

Compress 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.).

Improper cleaning methods and use of unauthorized cleaning solutions will injure personnel and damage equipment. See TM 9-247 for correct information.

3. Use compressed air to blow out all tapped capscrew holes and dry castings after cleaning.

e. Oil Passages. Particular attention must be given to all oil passages in castings and machined parts.

Oil passages must be clean and free of any obstructions.

1. Clean passages with wire probes to break up any sludge or gum deposits.

2. Wash passages by flushing with solvents. See TM 9-247.

3. Dry passages with compressed air.

CAUTION

Do not allow solvents to come in contact with seals, cables, or flexible hoses. These cleaners cause leather, rubber, and synthetic materials to dry out, rot, and lose pliability making then unserviceable.

f. Nonmetallic Parts. Clean hoses and other nonmetallic parts with soap and water.

0002 00-2

g. Bearings.

1. Bearings require special cleaning. After removing surface oil and gum deposits, place bearings in hot oil, 140°F (60°C), to loosen congealed oil and grease. Wipe bearings dry with a lint-free cloth; do not use compressed air.

2. See TM 9-214 for information and care of bearings.

h. Electrical Components.

1. Clean electrical components with clean cloth dampened with drycleaning solvent. Care must be taken not to damage protective insulation.

Do not use compressed air to dry bearings. Spinning a dry bearing with compressed air may cause injury to personnel or damage to equipment.

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.).

2. Use compressed air to dry electrical components.

GENERAL INSPECTION

a. General Instructions. Procedures for inspections will be the same for many parts and components which make up the vehicle subassemblies. General procedures are detailed in "b" through "k".

Dimensional standards for parts have been fixed at extremely close tolerances, so use specification tables. Use specified inspection equipment for inspection where cracks and other damage cannot be spotted visually. Exercise extreme care in all phases of inspection. Repair or replace all unserviceable components.

b. Castings.

1. Inspect all ferrous and nonferrous castings for cracks. See MIL-STD-6866, NDI Inspection, Penetrant Methods. Particularly check areas around studs, pipe plugs, threaded inserts, and sharp corners. Replace cracked castings.

0002 00-3

2. Inspect machined surfaces for nicks, burrs, and raised metal. Mark damaged areas for repair or replacement.

3. Inspect all pipe plugs, pipe plug openings, capscrews, and capscrew openings for damage and stripped threads. Replace if damaged or threads are stripped.

4. Check all gasket mating surfaces, flanges on housings, and supports for warpage with a straightedge or surface plate. Inspect mating flanges for discolorations which may indicate leakage. Replace if warped.

5. Check all castings for conformance to applicable repair standards. Refer to TM 9-214.

c. Bearings. Check all bearings for conformance to applicable repair standards.

d. Bushings and Bushing Type Bearings.

1. Check all bushings and bushing type bearings for secure fit, evidence of heating, wear, burrs, nicks, and out-of-round condition.

2. Check for dirt in lubrication holes or grooves. Holes and grooves must be clean and free from damage.

e. Machined Parts.

1. Check machined parts for cracks, distortion, and damage.

2. Check all surfaces for nicks, burrs, and raised metal.

f. Studs, Bolts, Capscrews, and Nuts. Replace if bent, loose, stretched, or threads are damaged.

g. Gears.

NOTE

When gear teeth wear limits are not established, good judgment is required to determine if gear replacement is necessary.

1. Inspect all gears for cracks and missing teeth. Replace if cracked or teeth are missing.

2. Inspect gear teeth for wear, sharp fins, burrs, and galled or pitted surfaces.

3. Inspect splines for wear, burrs, and galled or pitted surfaces.

4. Check keyway slots for wear and/or damage.

h. Oil Seals. Oil seals are mandatory replacement items.

0002 00-4

i. Casting Plugs. Inspect for leakage. Replace plugs when leakage is present.

Protective eye equipment (goggles/shield) must be worn when removing snaprings or springs. Failure to comply may result in injury to personnel.

j. Springs. Inspect for damaged, distorted, and collapsed coils.

k. Snaprings, Retaining Rings, and Washers. Many of these parts are mandatory replacement items.

Inspect all others for obvious damage.

GENERAL REPAIR

a. General Instructions. Repair of most parts and components is limited to general procedures outlined in applicable maintenance instructions and the following detailed procedures “b” through “h.”

CAUTION

Repaired items must be thoroughly cleaned to remove metal chips and abrasives to prevent them from entering working parts of vehicle components.

b. Castings.

1. All cracked castings will be replaced.

2. Only minor repairs to machined surfaces, flanges, and gasket mating surfaces are permitted. Remove minor nicks, burrs, and/or scratches by:

a. Using fine mill file.

b. Using abrasive cloth dipped in cleaning solvent.

c. Lapping across a surface plate.

d. Remachining of machined surfaced to repair damage, warpage, or uneven surfaces is not permitted. Replace castings.

3. Repair damaged threaded pipe plug and/or capscrew holes with a thread tap or repair oversize holes with threaded inserts.

c. Bearings. See TM 9-214.

d. Studs. Replace all bent and stretched studs. Repair minor thread damage with a thread restorer file.

Replace studs having stripped or damaged threads as outlined below:

1. Remove, using a stud remover. Back studs out slowly to avoid heat buildup and seizure which can cause stud to break off.

2. If studs break off too short to use a stud remover, use extractor to remove.

0002 00-5

3. Replacement studs have a special coating and must have a small amount of antiseize compound

(NSN 8030-00-059-2761) applied on threads before stud is installed. Install replacement stud slowly to prevent heat buildup and snapping off.

e. Gears.

1. Remove gears using pullers, as required.

2. Use the same methods described in paragraph b.2. (WP0002 00) for castings to remove minor nicks, burrs, or scratches on gear teeth.

3. If keyways are worn or enlarged, replace gear.

f. Bushings and Bushing Type Bearings. When bushings and bushing type bearings seize to a shaft and spin in the bore, the associated part must also be inspected and replaced, as required.

g. Oil Seals.

1. Remove oil seals, being careful not to damage casting or adapter bore.

2. Always install new seal in bore using proper seal replacing tool.

h. Locking Threads. When using thread sealing compound:

1. Apply a liberal amount to both male and female threads on through-hole assemblies.

2. Apply a liberal amount into the bottom of a blind hole (non-through hole assemblies). Installing the fastener pneumatically forces the adhesive onto the threads.

3. Assemble parts shortly after applying thread sealing compound to allow adequate coating of threads.

0002 00-6

CHAPTER 2

REPAIR

0003 00

TRANSFER CASE REPAIR (MODEL 242) DISASSEMBLY

Disassembly, Cleaning, Inspection and Repair, and Assembly

Tools General mechanics tool kit: automotive (NSN 5180-00-177-7033) Screw extractor set (NSN 5120-00-610-1888) Arbor press (PN AA51195)

Special Tools Slide hammer adapter (PN J 6471-8) Driver handle (NSN 5120-00-677-2259) Input gear seal installer (NSN 5120-01-389-9992) Bearing remover set (NSN 5120-01-201-7857) Input gear bearing installer (NSN 5120-01-185-7955) Output shaft front bearing remover/installer (PN J 33832) Extension bushing remover (NSN 5120-01-357-3631) Bushing remover/bearing installer (NSN 5120-01-357-3633) Extension housing seal installer (5120-01-361-3101) Output shaft seal installer (NSN 5120-01-277-1680) Bearing tool (NSN 5120-01-357-9123) Mainshaft pilot bearing installer (NSN 5120-01-389-9992) Seal installer (NSN 5120-01-414-1849) Seal installer (NSN 5120-01-437-0480) Drive handle (NSN 5120-01-026-1666)

Materials / Parts *See work package 7 for a list of mandatory Replacement Parts (Pg. 0007 001/-2 blank) Anaerobic gasket sealer (NSN 8030-01-374-3504 or NSN 8030-01-374-2338) Petrolatum (NSN 9150-00-250-0926 or NSN 9150-00-250-0933) Silicone sealant (NSN 8040-00-865-8991) Sealing compound (NSN 8030-00-165-6547) Transmission fluid (NSN 9150-00-698-2382 or NSN 9150-00-657-4959) Transfer case support stand (WP0008 00)

Equipment Condition Transfer case remove

0003 00-1

Disassembly

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

2. Remove O-ring (3) from pinion adapter (6). Discard O-ring (3).

3. Remove nut (7), front output yoke (8), and lockwasher seal (9) from transfer case (11) Discard lockwasher seal (9).

4. Move shift range lever (10) to most rear position.

5. Remove three capscrews (13) from rear extension (14) and rear retainer (5).

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

6. Use a soft nosed hammer or mallet on screw hole bosses (15) of rear extension (14) to break sealing bead and remove rear extension (14) from rear retainer (5).

7. Remove rear output shaft seal (12) from rear extension (14). Discard rear output shaft seal (12).

0003 00-2

0003 00-3

8. Remove snapring (1) from mainshaft assembly (2).

9. Remove four capscrews (3) from rear retainer (4) and rear half-case (5).

10. Prying on tabs of rear retainer (4), remove rear retainer (4) from rear half-case (5) and mainshaft (2).

11. Remove two snaprings (6) and speedometer drive gear (7) from mainshaft assembly (2).

0003 00-4

12. Remove two capscrews (10) and washers (11) from rear half-case (5).

Mark positions of long screws for installation.

13. Remove two long screws (9) from front output end of rear half-case (5).

14. Remove seven screws (8) from rear half-case (5).

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

15. Pry and remove rear half-case (5) from front half-case (17). Lay rear half-case (5) on bench with oil pump (15) up.

Mark position of oil pump to rear half-case before removal.

Failure to do so will cause damage to equipment.

0003 00-5

16. Rotate oil pickup tube (13) and oil screen (14) out of rear half-case (5) and pull pickup tube (13) out of oil pump inlet port (12).

17. Remove oil pump (15) from rear half-case (5).

18. Remove oil screen (14) and pickup tube (13) from hose (16).

19. Remove magnetic pickup (18) from pocket in front half-case (17).

0003 00-6

20. Remove oil tube seal (2) from oil pump (1). Discard oil tube seal (2).

21. Remove snapring (3) securing drive sprocket (4) on mainshaft assembly (5).

22. Remove drive sprocket (4) and drive chain (6) from front half-case (7).

23. Remove front output shaft (10) and driven gear (9) from front half-case (7).

24. Remove snapring (8) and driven gear (9) from front output shaft (10).

0003 00-7

25. Remove nut (22), washer (21), and shift lever (20) from sector shaft (19).

26. Remove plug (23) from low range fork access hole (18).

27. Using screw extractor in tapered drive pin (24), turn counterclockwise and withdraw tapered drive pin (24) from low range fork access hole (18). Discard tapered drive pin (24).

28. Remove shifter detent plug (17), O-ring (16.1), spring (16), and poppet (15) from front half-case (7).

Discard O-ring(16.1).

29. Remove two nuts (13), washers (12), and oil cooler (11) from front half-case (7).

30. Remove two O-rings (14) from oil cooler (11). Discard O-rings (14).

0003 00-8

31. Pull shift rail (5) out of mode shift fork assembly (4).

32. Remove mode shift fork assembly (4) and mainshaft assembly (1) out of front half-case (3) as a unit.

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

34. Remove mode shift sleeve (2) from mainshaft assembly (1).

35. Remove snapring (6) and keyed thrust washer (7) from mainshaft (1).

36. Slide intermediate clutch shaft (8) off mainshaft (1).

37. Remove differential snapring (10) from mainshaft (1).

0003 00-9

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

38. Remove differential assembly (9) from mainshaft (1).

39. Remove two thrust washers (11) and fifty-three needle bearings (12) from mainshaft (1).

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

41. Remove shift sector (5) from front half-case (4).

0003 00-10

42. Remove four screws (7) and bearing retainer (8) from front half-case (4). Pry on bearing retainer (8) at slots (11).

43. Remove input gear seal (6) from bearing retainer (8). Discard input gear seal (6).

44. Remove snapring (9) from input gear shaft (10).

0003 00-11

45. Supporting front half-case (4), use driver handle and input gear bearing installer to press on input gear shaft (10) and remove input gear shaft (10) and low range gear (15) from input bearing (16).

46. Remove snapring (12) from low range gear (15).

47. Turn and remove retainer (13) from housing of low range gear (15).

48. Remove two thrust washers (14) and input gear (10) from low range gear (15).

CLEANING

Clean all parts in accordance with Support Information – Work Package 0002.

INSPECTION AND REPAIR

1. Inspect all parts in accordance with Support Information – Work Package 0002.

0003 00-12

2. Repair all parts in accordance with Support Information – Work Package 0002 00.

3. Inspect front half-case (1) for cracks, nicks, burrs, blocked oil passages, and broken, missing, or damaged studs (7). Also check front input ball bearing (5) and front output ball bearing (4). Repair or replace damaged studs (7). Remove burrs and clear blocked oil passages. Replace front half-case (1) if cracked or broken at any machined surface. Remove and discard front output shaft seal (10). Replace front half-case (1) if annulus gear (2) is loose or damaged. Replace defective ball bearings as follows:

(a) Front output ball bearing (4).

(1) Remove snapring (3) from front half-case (1). (Use bearing remover tool for A2 vehicles.)

(2) Using driver handle, output shaft front bearing remover, and bearing tool, remove and inspect ball bearing (4) in front half-case (1).

(3) Install output shaft seal (10) in front half-case (1) with output shaft seal installer.

(b) Front input ball bearing (5).

(1) Using driver handle, input gear bearing installer, and arbor press, press ball bearing (5) out of front half-case (1).

(2) Remove snapring (6) from ball bearing (5).

(3) Install snapring (6) in ball bearing (5). (Use bearing installer tool for A2 vehicles.)

(4) Using wooden block, seat ball bearing (5) in front half-case (1). Seat ball bearing (5) until snapring (6) is against front half-case (1).

4. Inspect retainer (9) and O-ring (8) for damage. Replace if damaged.

0003 00-13

5. Inspect input gear (11) for breaks, cracks, broken or chipped gear teeth (12), scoring on sealing area (15), and damaged snapring groove (14). Inspect bearing (13). Replace input gear (11) if damaged.

Replace bearing (13) as follows:

(a) Mount input gear (11) in soft-jawed vise, gear end up.

(b) Install bearing remover to remove bearing (13).

(c) Use slide hammer and slide hammer adapter to remove bearing (13) from input gear (11).

(d) Coat bearing (13) with transmission oil and install in input gear (11) with driver handle and main pilot bearing installer.

6. Inspect rear half-case (17) for cracks, breaks, burrs, and plugged oil passages. Remove burrs. Replace rear half-case if cracked or broken. Inspect front output shaft rear bearing (16). Replace loose or damaged alignment retaining dowel (18). Replace front output shaft rear bearing (16) as follows:

(a) Using bearing remover, slide hammer and slide hammer adapter, remove bearing (16).

(b) Coat bearing (16) with transmission oil.

(c) Using driver handle and bearing installer, install bearing (16) in rear half-case (17).

0003 00-14

7. Inspect rear differential assembly (1).

(a) Mark front carrier (4) and rear carrier (3) cases for assembly.

(b) Remove three screws (2) from rear carrier (3) and turn rear carrier (3) over.

(c) Using slots (5), pry rear carrier (3) off front carrier (4).

Needle bearing will fall free when removing short pinion gears.

Refer to diagram on page 0003 00-17 for steps (d), (e) and (f).

(d) Remove six pinion washers (6), three long pinion gears (7), six thrust washers (12), three short pinion gears (8), and fifty-four needle bearings (13) from pins (10) on front carrier (4).

Record position of mainshaft gear (9), sprocket gear (11), and front carrier (4) for assembly.

(e) Remove mainshaft gear (9) and sprocket gear (11) from front carrier (4). Separate mainshaft gear (9) and sprocket gear (11).

(f) Inspect front carrier (4) for cracks, damaged threads, broken or chipped gear teeth, and loose or damaged pins (10). Replace front carrier (4) if damaged.

0003 00-15

(g) Inspect rear carrier (3) for cracks and breaks. Replace rear carrier (3) if damaged.

(h) Inspect short pinions (8) and long pinions (7) for cracks, chipped or broken gear teeth, and ridged or scored gear teeth. Replace three short pinions (8) and three long pinions (7), if any one is damaged.

(i) Inspect thrust washers (12) and pinion washers (6) for breaks, cupping, and scoring. Replace all thrust and pinion washers (12) and (6) if any one is damaged.

(j) Inspect mainshaft gear (9) and sprocket gear (11) for cracks, broken or chipped gear teeth, and cracks, gouges, or deep scoring on brass ring on bottom of mainshaft gear. Replace gear (9) or

(11) if damaged.

All transfer case parts must be lubricated with clean transmission oil before assembly. Foreign material will cause transfer case damage.

(k) Lay front carrier (4) on flat work table and place mainshaft gear (9) in rear carrier (3) with cone surface up.

(1) Install sprocket gear (11) on mainshaft gear (9). Splined hub of mainshaft gear (9) must be up.

0003 00-16

Use petrolatum to hold needle bearings in place on pins.

(m) Install three thrust washers (12), fifty-four needle bearings (13), three short pinion gears (8), and thrust washers (12) on pins (10).

(n) Install three pinion washers (6), long pinion gears (7), and pinion washers (6) on pins (10).

(o) Align index marks on front carrier (4) and rear carrier (3) and set rear carrier (3) over pins (10).

(p) Install front and rear carriers (4) and (3) with three screws (2).

8. Inspect mainshaft (1) for cracks, breaks, scored bearing surfaces (2), chipped or broken splines (5), damaged lockring groove (3), and damaged gear teeth. Clean oil passages (4). Repair minor scoring and remove burrs on mainshaft (1). Replace mainshaft (1) if damaged.

If any parts of oil pump fail inspection and cannot be repaired, replace oil pump.

0003 00-17

9. Inspect oil pump (6) for cracks, breaks, scoring, and damaged bushing and threads. Replace oil pump if any parts are damaged.

10. Inspect rear retainer (8) for cracks, breaks, damaged threads, and worn or damaged ball bearing (7).

Repair damaged threads. Replace rear retainer (8) if cracked, broken, or threads unreparable. Replace worn or damaged ball bearing (7). Replace loose or damaged alignment retainer dowel (9) if damaged.

(a) Use hammer and soft drift punch to remove ball bearing (7) from rear retainer (8).

(b) Seat ball bearing (7) in rear retainer (8) using driver handle and output shaft front bearing installer.

11. Inspect rear extension (12) for cracks, breaks, and worn or damaged bushing (11). Replace rear extension (12) if cracked or broken. Replace worn or damaged bushing (11) as follows:

(a) Remove defective bushing (11) using driver handle and extension bushing remover.

(b) Install bushing (11) in rear extension (12) using driver handle and bearing installer.

12. Inspect intermediate clutch shaft (10) for cracks, breaks, and bent or twisted splines. Replace intermediate clutch shaft (10) if damaged.

0003 00-18

13. Inspect shift sector (16) for burrs, cracks, breaks, loose shaft (17), and damaged threads. Remove minor burrs and repair minor thread damage. Replace shift sector (16) if cracked, broken, or loose or damaged shaft (17).

14. Inspect oil screen (13), hose (14), and pickup tube (15). Clean oil screen (13) and inspect for holes.

Replace oil screen (13) if damaged. Inspect tube (15), hose (14), and oil screen (13) for bends or cracks that would prevent sealing. Replace damaged parts.

15. Inspect range shift fork (16) for burrs, bends, and breaks. Remove burrs. Replace pads (6) if there is any wear. Replace range shift fork (16) if broken, cracked, loose pin (15) or damaged.

16. Inspect range clutch sleeve (17) and mode shift sleeve (7) for burrs, cracks, breaks, and damaged splines or gear teeth. Remove minor burrs. Replace range clutch sleeve (17) or mode shift sleeve (7) if damaged.

17. Inspect mode shift fork assembly (8) for cracks, breaks, bent brackets (2) and (14), and broken or deformed springs (4) and (10). If pads (6) are worn, replace pads (6). Replace bracket (14) if pin (15) is damaged. Mode shift fork assembly (8) must slide freely on shift rail (18) without excessive side free play. Inspect two bushings (5) for damage. Replace bushings (5) if damaged. If free play is excessive, replace mode shift fork assembly (8). Disassemble mode shift fork assembly (8) as follows:

0003 00-19

(a) Position mode shift fork assembly (8) in vise with bracket (14) secured in vise.

Mode shift fork assembly is under spring tension. Use care when compressing fork to release bracket.

(b) Press mode shift fork (8) down and tilt to free and remove mode shift fork assembly (8) from bracket (14).

(c) Remove bushing (11), spring (10), and thrust washer (9) from mode shift fork (8).

(d) Remove bracket (2), cup (3), and spring (4) from mode shift fork (8).

(e) Remove bracket (14) from vise.

Assemble mode shift fork assembly (8) as follows:

(a) Install bracket (14) in vise.

(b) Install spring (4), cup (3), and bracket (2) on short end of mode shift fork (8). Ensure open end of bracket (2) is positioned under mode shift fork lip (12).

(c) Install thrust washer (9), spring (10), and bushing (11) on mode shift fork (8).

(d) Position mode shift fork assembly (8) on bracket (14).

(e) Press mode shift fork (8) down and forward until tab (13) on bracket (2) is seated in bracket (14).

(f) Remove mode shift fork assembly (8) from vise.

0003 00-20

18. Inspect shift rail (18) for bends, cracks, and grooving. Replace shift rail (18) if damaged.

19. Inspect detent assembly for broken or kinked spring (20), broken or burred poppet (19), or damaged plug (22). Replace poppet spring seal (21) on plug (22). Replace plug (22), spring (20), or poppet (19) if damaged.

20. Inspect drive chain (23) for breaks, missing parts, kinks, and evidence of scratching on contact surfaces. Replace drive chain (23) if damaged.

21. Inspect drive sprocket (24) and driven gear (26) for cracks, breaks, bent or twisted splines, and broken or chipped gear teeth. Replace gears (24) or (26) if damaged.

22. Inspect front output shaft (25) for cracks, bent or twisted splines, damaged threads, and scored bearing and sealing surfaces. Minor scoring and thread damage is reparable. Replace front output shaft

(25) if damaged.

23. Inspect low range gear (29) for cracks, breaks, chipped or broken gear teeth, pinion side free play and smooth rotation. If front and rear carriers are loose, tighten screws (28); if still loose, replace low range gear (29). For all other damage, replace low range gear (29).

24. Inspect oil cooler (27) for bends, breaks, and leaks. Repair by straightening bent fins. Replace oil cooler (27) if damaged.

Pressure test at 3 psi or vacuum test assembly. No leaks allowed.

0003 00-21

ASSEMBLY

1. For general assembly instructions:

a. Cleanliness is essential in all component assembly operations. Dirt and dust, even in minute quantities, are abrasive. Parts must be cleaned as specified, and kept clean. Wrap or cover parts and components when assembly procedures are not immediately completed.

b. Coat all bearings and contact surfaces with operating oil (differential oil for differential parts, transmission oil for transmission parts, etc.) to ensure lubrication of parts during initial operation after repair.

2. Place thrust washer (3), input gear (5), thrust washer (3), and retainer (2) into low range gear (4) with snapring (1). Make sure snapring (1) is fully seated in groove of low range gear (4).

Use correct tool to press input gear into ball bearing. Pilot bearing could be moved out of position causing damage to equipment.

3. Using driver handle and main pilot bearing installer and supporting ball bearing (12), press input gear shaft (5) into ball bearing (12). Snapring groove must be exposed beyond ball bearing (12).

4. Install snapring (8) in input gear shaft (5).

0003 00-22

5. Using input gear seal installer, install input gear seal (10) in bearing retainer (9).

6. Run a bead of sealer on contact surface of bearing retainer (9).

7. Install bearing retainer (9) on front half-case (6) with four screws (11). Tighten screws (11) to 12-20 lb-ft (16-27 N·m).

8. Install shift sector (7) in front half-case (6).

9. Install shift lever (15) on shift sector (16) with washer (14) and nut (13). Tighten nut (13) to 20-25 lb-ft (27-34 N·m).

10. Install poppet (19), spring (18), and shift detent plug (17) in bore ( 20). Tighten plug to 12-18 lb-ft (16-24 N·m). Turn shift lever (15) so poppet (19) fits in teeth of shift sector (7).

0003 00-23

11. Position range shift fork (1) in range clutch sleeve (2).

12. Holding range shift fork (1) and range clutch sleeve (2) together, install range clutch sleeve (2) in input gear shaft (3) and pin (5) in angle slot (7) of shift sector (6). Move shift sector (6) as necessary to align fork (1).

13. Place thrust washer (8), fifty-three needle bearings (15), and thrustwasher (8) on mainshaft (14).

Use petrolatum to hold needle bearings (15) in place on mainshaft journal (14).

14. Carefully slide differential assembly (13) over mainshaft (14) and needle bearings (15) with snapring (12). Make sure that, no needle bearings (15) are displaced.

15. Place intermediate clutch shaft (11) over mainshaft (14).

0003 00-24

16. Position keyed thrust washer (10) over mainshaft (14) on intermediate clutch shaft (11) with snapring (9). Snapring (9) seats in groove in mainshaft (14).

17. Slide mode shift sleeve (18) onto mode shift fork (17).

18. Slide mode shift fork assembly (16) over mainshaft assembly (14) and align with differential assembly (13).

19. Lifting on end of mainshaft assembly (14), holding mode shift fork assembly (16) in place, set end of mainshaft assembly (14) into input gear in front half-case (4).

20. Carefully align pin (20) of mode fork (16) in long slot (24) of shift sector (6).

21. Align mode shift fork (16), and range shift fork (1) in front half-case (4) and insert shift rail (19) and seat in front half-case (4).

0003 00-25

• It may be necessary to use screw extractor to start tapered drive pin in range shift fork.

• It may be necessary to remove shift lever to install tapered drive pin.

22. Align pin hole in range shift fork (1) and shift rail (19) with hole (23) in front half-case (4) and install tapered drive pin (22) in shift rail (19).

23. Install plug (21) in front half-case (4).

24. Install two O-rings (12) and oil cooler (1) in front half-case (2) with two washers (11) and nuts (10).

25. Install driven gear (4) on front output shaft (5) with snapring (3).

26. Install front output shaft (5) and driven gear (4) in front half-case (2).

0003 00-26

27. Position drive chain (9) over mainshaft assembly (8) and driven gear (4).

28. Work drive sprocket (7) onto mainshaft assembly (8) and into drive chain (9) and mainshaft (8) with snapring (6).

29. Install oil tube seal (14) in pickup bore of front housing of oil pump (13).

30. Assemble oil screen (16), hose (17), and oil pickup tube (18).

31. Place oil pump (13) on rear half-case (15), insert pickup tube (18) into oil pump (13), and install oil screen (16) in rear half-case (15).

0003 00-27

32. Install magnet pickup (9) in socket (8) in front half-case (10).

33. Install two alignment dowels (5) in rear half-case (11) if they were removed.

Ensure flanges are clean and free of oil

34. Run a 1/8 in. (3 mm) bead of sealer on mating flange surface of the front half-case (10).

35. Position rear half-case (11) on front half-case (10) and install two washers (4) and capscrews (3) through alignment dowels (5) into front half-case (10). Turn mainshaft assembly (7) to align oil pump

(6) gears.

36. Install two long screws (2) at front output shaft area and seven screws (1) in remaining holes in rear half-case (11). Tighten screws (3), (2), and (1) to 26-34 lb-ft (35-46 N·m).

37. Install speedometer drive gear (16) on main shaft (7) with two snaprings (15).

38. Run a 1/8 in. (3 mm) bead of sealer on sealing surface of rear retainer (12) and install on rear halfcase (11) with four capscrews (14). Tighten capscrews (14) to 26-34 lb-ft (35-46 N·m).

0003 00-28

39. Install snapring (13) on mainshaft assembly (7). Lift mainshaft (7) as necessary to clear groove (17) for snapring (13). Ensure snapring (13) is fully seated in groove (17).

40. Run a 1/8 in. (3 mm) bead of sealer on flange sealing surface of rear retainer (12).

41. Using extension housing seal installer, install rear output seal (19) on rear extension (18).

42. Install rear extension (18) on rear retainer (12) with three capscrews (20). Tighten capscrews (20) to 26-34 lb-ft (35-46 N·m).

43. Install front output yoke (25) on shaft (23) with lockwasher seal (24) and nut (21). Tighten nut (21) to 90-130 lb-ft (122-176 N·m).

44. Install driven gear (30), O-ring (29), and pinion adapter (28) in rear retainer (12) with clamp (27) and capscrew (26). Tighten capscrew (26) to 12-15 lb-in. (1.4-1.7 N·m).

45. Move shift range lever (22) to make sure transfer shifts into four detent positions. May have to turn shafts to obtain full detent engagement.

0003 00-29

0003 00-30

0004 00

AFTER REPAIR TRANSFER CASE PERFORMANCE TEST

After Repair Transfer Case Performance Test

After Repair Transfer Case Performance Specifications

1. Rating

Gear Ratios:

Low Range 2.61:1 High Range and High Lock Range 1:1

You are not required to perform any specific submergence or environmental tests.

We expect the use of OEM and/or qualified after market gaskets and seals to achieve these requirements.

0004 00-1

0004 00

AFTER REPAIR TRANSFER CASE PERFORMANCE TEST

You will do a performance test on each transfer case repaired. A Quality Assurance (QA) Representative must witness this testing.

a. Testing Fixture

Provide a test stand with the following capabilities:

1. A rotating power source.

2. Controls to operate transfer case shift lever.

3. Pressure test at 3 psi or vacuum test assembly. No leaks allowed.

b. Setup

1. Transfer case shall be prepared for operation (properly lubricated) and installed in a suitable test fixture capable of simulating actual vehicle installation with all the necessary equipment to operate and monitor test.

2. Perform a free-running, no load, test by rotating the input shaft by hand in both directions.

a. Neutral. Shift transfer case to N (neutral). The input shaft and both output yokes must turn freely. Turning the input shaft should not turn the output yokes.

b. Low Lock. Shift the transfer case to L (low range). Turn the input shaft. Both output yokes must turn freely and smoothly.

c. High. Shift the transfer case to H (high range). Turn the input shaft. Each output yoke must turn freely and smoothly when the other is held stationary.

d. High Lock. Shift the transfer case to HL (high lock range). Turn the input shaft. Both output yokes must turn freely and smoothly.

0004 00-2

0005 00

PART DISPOSAL AND QUALITY ASSURANCE

Disposal and Quality Assurance

Disposal

You are responsible for disposal of any unrepairable or unused parts or assemblies.

Quality Assurance

The repair activity will implement and maintain a Quality Assurance program that complies with ISO 9002 (dated 1994, tailored), “Quality System – Model for Quality Assurance in Production, Installation and Servicing.”

0005 00-1/2 blank

0006 00

SPECIAL PACKAGING INSTRUCTIONS

Special Packaging Instructions

Special Packaging Instructions

Additional Packaging information can be found in this Web site. You must enter the Part Number at the Query screen. You will need to have the ImageR viewer to view the images. You can down load the viewer from the Web Site by going to Help and following the directions. You will have to “cut/paste” the address below to your address bar.

Pkg 1 79.C4

Pkg 2 82.C4

Pkg 3 80.C4

Pkg 4 81.C4 https://www-tdps.tacom.army.mil/PackagingHome.htm

0006 00-1/2 blank https://www-tdps.tacom.army.mil/PackagingHome.htm

0007 00

MANDATORY REPLACEMENT LIST

Mandatory Replacement List

MANDATORY REPLACEMENT LIST

Mandatory replacement parts listed are those parts considered unserviceable after removal during disassembly procedures. All gaskets, seals, cotter pins, and standard stock of this type will be replaced as well as all components considered incapable of proper performance until the next rebuild / recapitalization effort. The Silent Chain, NSN 3020-01-358-8601 and Fork Pads will be replaced in all cases. To eliminate the necessity of more costly inspections, all other items of negligible cost are also to be replaced.

ITEM DESCRIPTION PART NUMBER NSN QTY

Pinion adapter O-ring 12339002 5330-01-195-8889 1 Two O-rings 16080 5330-01-209-7726 2 Seal, lockwasher 12338062 5310-01-148-2687 1 Seal, oil tube 35208 5330-00-477-2048 1 Poppet spring O-ring 15715 5331-01-358-9545 1 Input gear seal 5740017 5330-01-168-3870 1 Front output shaft seal 18771 5330-01-358-9532 1 Rear output drive seal 16104 5330-01-358-9540 1 Pin, tapered drive 1664355 5315-00-576-0265 1 Bushing 811681 5365-00-424-3777 1 Silent Chain 17577 3020-01-358-8601 1 Pad, Fork, Transfer 5740114 2520-01-162-8985 4

0007 00-1/-2 blank

0008 00

TEST STAND FABRICATION

0008 00-1/-2 blank

AMSTA-LC-CIP-WT

U.S. ARMY TACOM-RI

1 Rock Island Arsenal Rock Island, IL 61299-7630

This NMWR was prepared under the control of the Commanding General and the Equipment Publication Control Officer, TACOM and is published for the information and guidance of all concerned.

FOR THE COMMANDER:

OFFICIAL:

PHILLIP B. OWENS

Colonel, GS Chief of Staff

RONALD R. GEDYE

Equipment Publication Control Officer T.00254

DISTRIBUTION: Special

TYPED NAME, GRADE, OR TITLE

Pat Smith

TELEPHONE EXCHANGE/AUTOVON,

PLUS EXTENSION

AV272-4162

SIGNATURE

Pat Smith

DATE:

ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON

NO. NO. GRAPH NO.* NO. NO. (Provide exact wording of recommended changes, if possible).

USAPPC V3.00DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

RECOMMENDED CHANGES TO

PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is ODISC4.

Use Part II (reverse) for Repair Parts and Special Tools Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

TO: (Forward to proponent of publication or form) (include ZIP code)

AMSTA-LC-LMIT Tech Pubs, TACOM-RI 1 Rock Island Arsenal Rock Island, IL 61299-7630

PUBLICATION/FORM NUMBER

NMWR 9-2520-584

DATE

28 February 2007

TITLE

HMMWV Transfer Case

FROM:(Activity and location) (include ZIP code)

PART I - ALL PUBL ICAT IONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS

*Reference to line numbers within the paragraph or subparagraph.

0007 00-3 Figure 2, Item 9 should show a lockwasher. Currently shows a flat washer.

0018 00-2 Cleaning and inspection, Step 6, reference to governor support pin (14) is wrong reference. Reference should be changed to (12).

SAMPLE

30 November 2006

Co. B, 1st BN, 2nd Brigade Ft. Hood, TX 76445

TYPED NAME, GRADE, OR TITLE TELEPHONE EXCHANGE/AUTOVON,

PLUS EXTENSION

SIGNATURE

DATE:

TOTAL NO.

OF MAJOR

PAGE COLM LINE NATIONAL REFERENCE FIGURE ITEM ITEMS RECOMMENDED

NO. NO. NO. STOCK NUMBER NO. NO. NO. SUPPORTED ACTION

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

AMSTA-LC-LMIT Tech Pubs, TACOM-RI 1 Rock Island Arsenal Rock Island, IL 61299-7630

FROM: (Activity and location) (include ZIP code)

PUBLICATION/FORM NUMBER

NMWR 9-2520-584

DATE

28 February 2005

TITLE

HMMWV Transfer Case

PART I I - REPAIR PARTS AND SPECIAL TOOLS L ISTS AND SUPPLY CATALOGS/SUPPLY MANUALS

PART I I I - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank forms.

Additional blank sheets may be used if more space is needed.)

SAMPLE

AMSTA-LC-LMIT Tech Pubs, TACOM-RI 1 Rock Island Arsenal Rock Island, IL 61299-7630

28 February 2007 HMMWV Transfer Case

AMSTA-LC-LMIT Tech Pubs, TACOM-RI 1 Rock Island

ArsenalRock Island, IL 61299-7630

NMWR 9-2520-584 28 February 2007 HMMWV Transfer Case

LINEAR MEASURE

1 Centimeter = 10 Millimeters = 0.01 Meters =

0.3937 Inches

1 Meter = 100 Centimeters = 1,000 Millimeters =

39.37 Inches

1 Kilometer = 1,000 Meters = 0.621 Miles

SQUARE MEASURE

1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Miles

CUBIC MEASURE

1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet

LIQUID MEASURE

1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1,000 Milliliters = 33.82 Fluid Ounces

TEMPERATURE

Degrees Fahrenheit (F) = °C • 9 ÷ 5 + 32 Degrees Celsius (C) = F° - 32 • 5 ÷ 9 212° Fahrenheit is equivalent to 100° Celsius 90° Fahrenheit is equivalent to 32.2° Celsius 32° Fahrenheit is equivalent to 0° Celsius

WEIGHTS

1 Gram = 0.001 Kilograms = 1,000 Milligrams =

0.035 Ounces

1 Kilogram = 1,000 Grams = 2.2 Lb 1 Metric Ton = 1,000 Kilograms = 1 Megagram = 1.1 Short Tons

THE METRIC SYSTEM AND EQUIVALENTS

APPROXIMATE CONVERSION FACTORS

TO CHANGE . . . . . . . . . . . . . . . . . . . . TO . . . . . . . . . . . . . . . . . . . . . . . .MULTIPLY BY Inches . . . . . . . . . . . . . . . . . . . . . . . . . Millimeters . . . . . . . . . . . . .