Telephone:(925) Fax:(925) Lawrence Drive, Livermore, CA

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2 Table of Contents This manual covers single and dual rear output versions of the TC- two-speed transfer case with either manual or air shift controls. Transfer Case Housing and Related Parts Shafts and Related Parts (Dual Rear Output Version) Shafts and Related Parts (Single Rear Output Version) 6 Shift Shafts and Related Parts (Manual Shift) 8 Shift Shafts and Related Parts (Air Shift) 0 Overhaul Kits To Use This Book:. Refer to the exploded view which illustrates the needed part.. Find the required part in the exploded view and then note the item number or numbers.. Locate the item number in the parts list for part number, description, and quantity. Note:. Before ordering parts for a Fabco transfer case, please refer to the Fabco nameplate located on the transfer case housing. Specify model number, serial number, part number, or other information that is on the nameplate when ordering parts. Part numbers contained in this manual were in effect at the time the manual was approved for printing and are subject to change without notice or liability. Fabco Automotive Corporation reserves the right to change parts at any time. 6

3 7 Transfer Case Housing and Related Parts

4 Transfer Case Housing and Related Parts 8 ITEM PART NO. DESCRIPTION QUANTITY 65 8 Bolt, '/ls- x ¾ Grade Carrier, Upper Shaft Front Seal 7 9 Gasket, Seal Carrier Housing, Transfer Case 7 5 Carrier, Upper and/or Lower Shaft Rear Seal (see note ) (As Required) 5 75 Cap, Upper Shaft Rear Bearing (see note ) (As Required) 86 Vent, Breather 5 56 Cap, Intermediate Shaft Front 7 8 Gasket, Intermediate Shaft Front Cap 7 Gasket, Intermediate Shaft Rear Cap 5 7 Cap, Intermediate Shaft Rear 7 9 Carrier, Lower Shaft Seal 7 5 Bracket, Lower Shaft x Brake Mounting (see note ) 7 Bracket, Lower Shaft 9 x Brake Mounting (see note ) (As Required) 7 98 Gasket, Cover Plate Plate, Cover 659 Bolt, '/ls- x Grade 5 With Lockwasher Plug, ¾ Square Head Fill Plug, ¾ Magnetic Drain 7 Shim, Rear Cap (Coral.0 ) (As Required) 7 Shim, Rear Cap (Pink 06") (As Required) 7 Shim, Rear Cap (Blue.005 ) (As Required) Notes:. Two () item 5 required for dual rear output transfer cases. One () item 5 required for dual rear output transfer cases with a parking brake assembly. One () item 5 required for single rear output transfer cases without parking brake.. One () item required for transfer cases with a parking brake assembly, only.. One () item 6 required for transfer cases with a single rear output.

5 9 Shafts and Related Parts (Dual Rear Output)

6 Shafts and Related Parts (Dual Rear Output) ITEM PART NO. DESCRIPTION QUANTITY Nut, ¼-8 Self Locking 97 9 Washer, O.D. Steel 7 6 Seal, Input and Front Output 76 6 Ring, (.000 Wide) Spacer 5 Bearing, Double Row Ball 78 Gear, (9 Tooth) Underdrive 76 8 Ring, Retaining 7 9 Shaft, Input 6 Gear, (0 Tooth) Clutch 7 Bearing, Stem Gear Ball 6 Gear, (5 Tooth) Stem Ring, Bearing Spacer 88 Sleeve, Seal 7 8 Seal, Rear Output Nut, -0 Self Locking Gear, Speedometer Drive 5 Gear, Speedometer Driven Sleeve, Speedometer Driven Gear 76 9 Ring, (.85 Wide) Speedometer Gear Spacer 97 Washer, (.0598 Wide) Spacer Bearing, Underdrive Gear Ball 77 Gear, ( Tooth) Underdrive *Shaft, Intermediate 76 6 *Ring, (.09 Wide) Spacer 8 *Gear, ( Tooth) Intermediate Shaft Direct Drive 66 Bearing, Roller 97 7 Washer, ¼ O.D. Steel 5 Bearing, Output Shaft Ball 7 67 Shaft, Front Output *Items,, and 5 may be purchased as Intermediate Shaft Gear Sub-Assembly, part number 8.

8 Shafts and Related Parts (Single Rear Output) ITEM PART NO. DESCRIPTION QUANTITY Nut, ¼-8 Self Locking 97 9 Washer, O.D. Steel 7 6 Seal, Input and Front Output 76 6 Ring, (.00 Wide) Spacer 5 Bearing, Double Row Ball 78 Gear, (9 Tooth) Underdrive 76 8 Ring, Retaining **Shaft, Input (used with bearing locknut equipped shafts) Shaft, Input 6 Gear, (0 Tooth) Clutch Bearing, Ball 7 Gear, (5 Tooth) Direct Drive 76 5 Ring, (.696 Wide) Spacer 97 Washer, (.059 Wide) Spacer 8 Bearing, Upper Shaft Rear Ball 688 **Nut, Bearing Retaining 97 8 *Washer, Bearing Lock Nut, -0 Self Locking Gear, Speedometer Drive 5 Gear, Speedometer Driven Sleeve, Speedometer Driven Gear 76 9 Ring, (.85 Wide) Speedometer Gear Spacer 77 Gear, ( Tooth) Underdrive *Shaft, Intermediate 76 6 *Ring, (.09 Wide) Spacer 8 *Gear, ( Tooth) Intermediate 66 Bearing, Roller 97 7 Washer, ¼ O.D. Steel 5 Bearing, Output Shaft Ball 7 67 Shaft, Front Output 7 Bearing, Stem Gear Ball 6 Gear, (5 Tooth) Stem Ring, Bearing Spacer 7 8 Seal, Rear Output Notes: *Items,, and 5 may be purchased as Intermediate Shaft Gear Sub-Assembly part number 8. **Used on early production transfer cases.

10 Shift Shafts and Related Parts (Manual Shift) ITEM PART NO. DESCRIPTION QUANTITY Bolt, ¼-0 x Seal Carrier, Seal Gasket, Shift Shaft Shaft, H-N-U Shift (Dual Rear Output) Ball, Diameter Spring, Detent Set Screw, Fork, Shift Screw, Set Fork, Shift Wire, 8 Ga. (.08) x 5½ Lock Cap, Shift Shaft Bolt, ¼-6 x ½ Shaft, Front Drive Shift Plunger Washer, Copper Switch, Indicator Light (Not Used) Fork, Front Drive Shift Shaft, H-N-U Shift (Single Rear Output) 8 8

12 Shift Shafts and Related Parts (Air Shift) ITEM PART NO. DESCRIPTION Bolt, ¼-0 x Cap, Shift Shaft Gasket, Shift Shaft Shaft, H-N-U Shift (Dual Rear Output) Fork, Shift Screw, Set Fork, Shift Wire, 8 Ga. (.08) x 5½ Lock O-Ring (¾ I.D.) Tube, Shift Cylinder Adapter Spring, Shift Shaft Ring, Stop O-Ring, Piston Seal Wiper, Felt Piston, Shift O-Ring. ( I.D.) Washer, Piston Nut Nut, Flexlock Tube, Shift Cylinder (.8 Long) Cap, Shift Cylinder Bolt, ¼-0 x 5 Grade 5 Bolt, ¼-0 x Grade 5 Tube, Shift Cylinder (.9 Long) Fork, Front Drive Shift Shaft, Front Drive Shift Plunger Washer, Copper Switch, Indicator Light Shaft, H-N-U Shift (Single Rear Output) QUANTITY 8 6

13 Overhaul Kits PART NO. DESCRIPTION 7 09 Gasket and Seal Kit (Air Shift Single Rear Output) 7 Gasket and Seal Kit (Air Shift Dual Rear Output) 7 Gasket and Seal Kit (Manual Shift Single Rear Output) 7 Gasket and Seal Kit (Manual Shift Dual Rear Output) 0 Bearing Kit (Dual Rear Output) 05 Bearing Kit (Single Rear Output) 7

chamfered end pointing as indicated and into the forked section of the shift fork.. Install the shift shaft (Item 9 on Page PM) or (Item 5 on Page PM). Install locknut (Item 7 on Page PM or PM).

14 IX. Assembly of PTO Unit (On Cases so Equipped) Refer to Illustration on Page PM. Put shift fork (Item 59) into housing (Item 6) with the chamfered side of the shift shaft hole toward the two opening ends of the housing, put clutch collar (Item 60) into the housing (with the chamfered end pointing as indicated and into the forked section of the shift fork.. Install the shift shaft (Item 9 on Page PM) or (Item 5 on Page PM). Install locknut (Item 7 on Page PM or PM). Restrain nut with a box wrench and turn the shaft with an open end wrench. 6. Remove bolts (Item 68), install shim, reinstall. Press bearing cones (Item 6) onto shaft (Item bolts with Permatex on their threads. Tighten to 65). Press seal (Item 69) into bearing carrier the specified torque. Skip to J8 if case is (Item 67). Press one cup (Item 6) into carrier. equipped with an air operated PTO shift.. Install shaft (Item 65) with bearing cones into the carrier sub-assembly and install the second bearing cup (Item 6). 5. Install the bearing carrier shaft assembly onto the housing (Item 6) with the shaft passing into the shift collar. Temporarily bolt the carrier to the housing. With bolts (Item 68) tightened to 5 ft. lbs., measure gap between the parts. Select a shim stack that measures.005 to.00 larger than the gap measurement. 7. Refer to Page PM. Install the manual shift linkage as follows: a. Oil and install o-ring (Item ) on seal carrier (Item 5). Install seal (Item 7). Lubricate inside of seal carrier and the seal with Lubriplate or transfer case oil. b. Fit seal carrier onto the shift shaft and into the shift opening on the PTO housing. The detent ball opening should be facing in the same general direction as the indicator light switch hole. Install the four bolts (Item 5), tightening to specifications. c. Put nut (Item 56) on eye (Item 57). Install (Item 57) onto end of shift shaft (Item 5). Install detent ball (Item ), detent spring (Item ) and set screw (Item 0). Tighten set screw until it takes a force of 5-0 Ibs. to push the shift shaft out of detent. Fig. 7 d. Position lever (Item 58) on eye (Item 57) with pin (Item 59) washers (Item 60) and cotter pin installed as illustrated on the oil line and fitting illustration (Page PM5). Install link (Item 55) as illustrated. Check shift action before tightening lock nut (Item 56). The eye should be adjusted as necessary to make the lever angles approximately even in the engaged and disengaged positions. Skip section J8 and proceed with step J9. 8

15 8. Refer to Page PM, install the Air Operated PTO Shift as follows: Oil o-rings (Item ), install on adaptor (Item 50). Place adaptor over shift shaft and into the PTO housing with the counterbored end outboard. Place o-ring (Item ) carefully over the end of the shift shaft. Position spring (Item 5) over the shift shaft and into the adaptor (Item 50). Place bump ring (Item ) over spring (Item 5). Move shift collar and restrain to make shift shaft project as far as possible. Install piston (Item 9), washer (Item 7) and nut (Item 6). Tighten nut to specified torque. Install felt ring (Item 0) (after soaking in transfer case lubricant) in wide groove of piston. Oil o-ring (Item 8) and install in the outboard groove of the piston. Install cylinder cap. Slip the shift cylinder tube (Item ) long) over the piston, onto the adaptor. Fit the shift cylinder cap into place and install the four capscrews that retain the assembly to the PTO unit, tighten to the specified torque. the piston, check valve and retaining ring assembly with transfer case lubricant. Put the spring (Item 76) into the counterbore of the piston and then put the cylinder over the spring and piston. Push the piston into the cylinder until the end of the cylinder is just even with the port in the side of the cylinder. The piston should move freely without binding. Screw the cylinder into the PTO bearing carrier (See Fig. 9). Rotate the PTO shaft to place the high point Fig Install the indicator light switch (Item 0) with same washers (Item ) as were removed during disassembly. Check switch operation with a continuity tester (and air pressure applied to the shift cylinder, if so equipped). 0. Install the blanking sleeve (Item 70) on the PTO output to seal the output shaft section of the PTO, if a yoke is not to be installed immediately.. The PTO unit includes an oil pump that consists of items 7 through item 80 on Page PM. Also refer to Fig. 9. The piston (Item 7) is driven by the eccentric section of shaft (Item 65). A check valve (Item 7) is retained within the piston by a spring type retaining ring (Item 75). This check valve must be installed with the free flow direction and arrow direction pointing toward the PTO shaft. This allows a small portion of the oil pump output to be directed onto the shaft s eccentric surface. Screw nut (Item 77) onto cylinder (Item 79) with nylon portion pointing away from the hexagon section of the cylinder. Coat of the cam under the piston, screw the cylinder in until the outer end of piston is visible short of the cylinder side port. Rotate the PTO shaft to verify that it is indeed on the high point of the cam. Screw the cylinder in until the outer end of the piston is just even with the side port; unscrew cylinder at least one turn, but not more than one and one half turns; tighten lock nut against the PTO bearing carrier with one side port of the cylinder pointing in the direction shown on Page PM5. Use pipe dope on all pipe threaded fittings. Screw check valves (Item 80) into place in the cylinder. The inlet check valve should be installed (with the arrow pointing into cylinder) in the end of the cylinder. The outlet valve should have the arrow pointing away from the cylinder and should be in the position shown on Page PM5 to allow the hose (Item ) to be used to connect the pump to fitting (Item 5) at the front of the case. 8. Refer to section VI G, paragraph for installation of the PTO unit on the transfer case. Also See Fig. and Fig Refer to Page and Page PM5 for the proper installation of the oil lines. Also see Fig.,, and Check oil flow out of oil pump upon installation. Refer to Section III B of this manual. 9

17 H-N-U Air Shift H-U Air Shift ITEM PART NO. DESCRIPTION Plastic Plug 5 7 Cap, Air Shift Cyl. 675 O-Ring, Air Shift Cap & Adaptor Nut, Shift Piston 97 6 Washer, Shift Piston O-Ring, Shift Piston 75 Piston, Shift 9 Felt Ring, Shift Piston O-Ring, Shift Shaft Ring, Nylon Bump Spring, Air Shift Return Adaptor, Air Shift Cyl. 7 Set Screw 97 Lockwire 7 99 Gasket, Shift Shaft Cap 5 7 Cap, Shift Shaft 65 Capscrew, ¼-0 x ½ Fork, Direct Drive Shift Fork, Under Drive Shift Shaft, H-N-U Air Shift Tube, Shift Cyl Nut, Special 7 58 Set Screw, x ¼ Allan Head Adaptor, Piggyback Cyl Shaft, Piggyback Cyl Tube, Piggyback Cyl. & PTO Cyl Stud, Piggyback Cyl. Mtg. 688 Nut, ¼-8 QUANTITY 5 ITEM PART NO. DESCRIPTION Plastic Plug 5 7 Cap, Air Shift Cyl. 675 O-Ring, Air Shift Cap & Adaptor Nut, Shift Piston 97 6 Washer, Shift Piston O-Ring, Shift Piston 75 Piston, Shift 9 Felt Ring, Shift Piston O-Ring, Shift Shaft Ring, Nylon Bump Spring, Air Shift Return Adaptor, Air Shift Cyl. 7 Set Screw 97 Lockwire 7 99 Gasket, Shift Shaft Cap 5 7 Cap, Shift Shaft 65 Capscrew ¼-0 x ½ Fork, Direct Drive Shift Fork, Under Drive Shift Shaft H-N-U Air Shift Tube, Shift Cyl Capscrew, Air Shift Cyl. ½-0 x ¾ QUANTITY

18 The following parts are for PTO equipped cases: ITEM PART NO. DESCRIPTION Fork, PTO Shaft 55 Collar, Sliding Clutch Housing, Main PTO 7 5 Capscrew, x ½ () Point 9 Bearing Cup Bearing Cone Shaft, PTO 7.0 Coral Shim 7.06 Pink Shim Blue Shim 7 5 Carrier, Bearing & Seal 65 Capscrew, -6 x 7 68 Seal, PTO Output 88 9 Tube, PTO Output (Temporary) Washer, PTO Output Yoke Nut, PTO Output Yoke QUANTITY A/R A/R A/R ITEM PART NO. DESCRIPTION QUANTITY 7 75 Piston, PTO Oil Pump Valve, PTO Piston Check Retaining Ring, PTO Piston Check Valve Spring, PTO Oil Pump Nut, PTO Oil Pump Cyl. Lock & Seal Plug, ¼ NPT PTO Oil Pump Cyl Cylinder, PTO Oil Pump Valve, PTO Oil Pump In & Out Check Washer, Copper Switch (If Specified) Plug, 8 Plastic PTO

19 AIR OPERATED PTO SHIFT ITEM PART NO DESCRIPTION Plastic Plug Cap, Air Shift Cyl. O-Ring, Air Shift Cap & Adaptor Nut, Shift Piston Washer, Shift Piston O-Ring, Shift Piston Piston, Shift Felt Ring, Shift Piston O-Ring, Shift Shaft Ring, Nylon Bump Plastic Plug Switch, Indicator Washer, Copper Capscrew, Air Shift Cyl. ½-0 x ¾ Tube, Piggyback Cyl. & PTO Cyl. Nut, PTO Shift Shaft Fork, PTO Shift Shaft, PTO Air Shift Adaptor, PTO Air Shift Cyl. Spring, PTO Air Shift Cyl. QUANTITY

20 ITEM PART NO. DESCRIPTION 675 O-Ring, Air Shift Cap & Adaptor Plastic Ring Switch, Indicator 97 7 Washer, Copper Seal, Shift Shaft Set Screw, Nylock Spring, Detent 5 Ball, Detent Nut, PTO Shift Shaft Fork, PTO Shift Carrier, Shift Shaft & Seal Shaft, PTO Shift-Manual Bolt, ¼-0 x ¾ Link, Connecting Nut, Jam 57 9 Eye Bolt Lever, PTO Shift Pin, Clevis w/cotter Pin Washer QUANTITY MANUAL PTO SHIFT

21 Oil Lines & Fittings PTO ITEM PART NO. DESCRIPTION Fitting, ½ MP H JIC Hose Assembly, Suction Fitting, ¼ FP H JIC Hose Assembly, Pressure Elbow, ¼ MP H QUANTITY

Telephone:(925) Fax:(925) Livermore, California 94551

Telephone:(925) Fax:(925) Livermore, California 94551 Telephone:(925)454-9500 Fax:(925)454-9501 Livermore, California 94551 VIII. PARTS MANUAL TC-35 PARTS MANUAL INDEX SECTION THROUGH ASSEMBLED SHAFTS PM2 EXPLODED VIEWS WITH PARTS LISTS Front Output Shaft