TC 142 & TC 1421 TRANSFER CASE

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1 AUTO MO TIVE CORPORATION TC 4 & TC 4 TRANSFER CASE PARTS MAN UAL FABCO AUTOMOTIVE CORPORATION, Livermore, CA Ph: (95) Fax: (95) (800)

2 8.0 ILLUSTRATED PARTS TABLE OF CONTENTS FIGURE Upper Shaft Intermediate Shaft, TC-4 Intermediate Shaft, TC-4 Lower Shaft, TC-4 Lower Shaft, TC-4 Front Output Shaft PTO Output Shaft Hydraulic Pump Drive Mounting Air Shift Cylinder for Declutches Air Shift Cylinder for Direct and Underdrive, TC-4 Air Shift Cylinder for Direct, Neutral and Underdrive, TC-4 Air Shift Cylinder for Direct and Neutral, TC-4 Housing and Filter TO USE THIS ILLUSTRATED PARTS SECTION. Refer to the figures which illustrate the needed part.. Find the required part and note the item number and quantity.. Locate the item number in the parts list section for the required part number and description. NOTE: When ordering parts, specify transfer case model number, part number, serial number or other information that is on the Fabco nameplate located on the transfer case housing. 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 anytime. USE ONLY GENUINE FABCO PARTS VN:6/90

3 FIGURE 8., TC-4 & TC-4, UPPER SHAFT PARTS

4 FIGURE 8., TC-4, INTERMEDIATE SHAFT PARTS

5 FIGURE 8., TC-4, INTERMEDIATE SHAFT PARTS

6 FIGURE 8.4, TC-4, LOWER SHAFT PARTS

7 FIGURE 8.5, TC-4, LOWER SHAFT PARTS

8 FIGURE 8.6, TC-4 & TC-4, FRONT OUTPUT SHAFT PARTS

9 FIGURE 8.7, TC-4 & TC-4, PTO OUTPUT SHAFT PARTS

10 FIGURE 8.8, TC-4 & TC-4, HYDRAULIC PUMP DRIVE MOUNTING PARTS

11 FIGURE 8.9, TC-4 & TC-4, AIR SHIFT CYLINDER PARTS FOR THE FRONT OUTPUT DECLUTCH, PTO OUTPUT DECLUTCH & HYDRAULIC PUMP DRIVE DECLUTCH

12 FIGURE 8.0, TC-4, AIR SHIFT CYLINDER PARTS FOR DIRECT & UNDERDRIVE

13 FIGURE 8., TC-4, AIR SHIFT CYLINDER PARTS FOR DIRECT, NEUTRAL & UNDERDRIVE

14 FIGURE 8., TC-4, AIR SHIFT CYLINDER PARTS FOR DIRECT & NEUTRAL

15 FIGURE 8., TC-4 TC-4, HOUSING & FILTER PARTS

16 9.0 PARTS LIST ITEM PART NO. DESCRIPTION TC-4 TC-4 FOOT QTY QTY NOTE Bearing Cup Bearing Cup Bearing Cone Bearing Cup Bearing Cone Bearing Cup & Cone Assembly Bearing Cup & Cone Assembly Bearing Cup & Cone Assembly Bearing Cone Bearing Cup Bearing Cone Bearing Cup Bearing Cone Cap, Shift Cylinder Cap, Shifter Shaft, Front Cap, Oil Pump Cap, Shift Cylinder, Inside Recessed Cap, Upper Shaft, Rear Cap, Intermediate Shaft, Front Cap, Intermediate Shaft, Rear 7 57 Carrier, Upper Shaft, Front 7 9 Carrier, Bearings & Seal, PTO Output 7 47 Carrier, Bearings & Seal, Front Output Carrier, Lower Shaft, Rear Bolt, H.H. /- x / Bolt, H.H. 7/6-4 x / Bolt, H.H. 7/6-4 x Bolt, H.H. 5/6-8 x / Bolt, H.H. 5/6-8 x Bolt, H.H. /4-0 x / 8 8 VP:4/98 SECT 9 PG

17 9.0 PARTS LIST CONT D. ITEM PART NO. DESCRIPTION TC-4 TC-4 FOOT QTY QTY NOTE Bolt, H.H. /- x / Bolt, H.H. /4-0 x /4 Bolt, H.H. 7/6-0 x /8, Grade 8 with Drilled Head Bolt, H.H. /4-0 x /4 Bolt, H.H. /4-0 x 4 / Bracket, Filter Mounting Felt Wiper Filter, Oil Nipple, Oil Filter Fork, Shift, Declutches Fork, Shift, Direct Gasket, Upper Shaft, Front Gasket, Declutch Carriers Gasket, Declutch Covers Gasket, Shifter Shaft Cap, Front Gasket, Intermediate Cap, Rear Gasket, Lower Carrier, Rear Gasket, Housing Cover Gear, Clutch Collar, Declutches Gear, Speedo Driven, T Gear, Speedo Drive, 6T Gear, Clutch Collar, Clutch Teeth Gear, Clutch Collar, Tapered Clutch Teeth Gear, Pump Drive 4 56 Gear, Clutch, Declutches Gear, Declutch Gear, Intermediate Shaft, Spur, 49T Gear, Intermediate Shaft, Helical, 47T Gear, Upper Shaft, Spur, 48T 4 68 Gear, Upper Shaft, Helical, 45T VP:4/98 SECT 9 PG

18 9.0 PARTS LIST CONT D. ITEM PART NO. DESCRIPTION TC-4 TC-4 FOOT QTY QTY NOTE Gear, Intermediate Shaft, Spur, T 4 68 Gear, Intermediate Shaft, Helical, 9T Gear, Lower Shaft, Spur, 66T Gear, Lower, 6 Helical Teeth Gear, Lower, 6 Helical Teeth and Tapered Clutch Teeth Gear, Lower Shaft, Spur 48T Gear, Lower, 45 Helical Teeth Gear, Lower, 45 Helical Teeth and Tapered Clutch Teeth Housing, Declutch, PTO Output Housing, Declutch, Front Output Housing, Transfer Case O-Ring, Shifter Shaft, Direct O-Ring, Shift Cylinders O-Ring, Shift Pistons Nut, Jam, / Nut, Hex, / Nut, Lock, / Nut, Lock, / Nut, Lock, Nut, Lock, / Nut, Lock, / Nut, Lock, / Nut, Lock, / Nut, Lock, / Screw, Socket Set, Lock, /8-6 x 5/ Screw, -pt, 7/6-4 x / Seal, Oil, Input, Front & PTO Outputs Seal, Oil, Rear Output Stop Ring, Piston 4 VP:4/98 SECT 9 PG

19 9.0 PARTS LIST CONT D. ITEM PART NO. DESCRIPTION TC-4 TC-4 FOOT QTY QTY NOTE Spacer Bearing,.60 Thick, Front Output Shaft Spacer Bearing,.65 Thick, Front Output Shaft Spacer Bearing,.70 Thick, Front Output Shaft Spacer Bearing,.75 Thick, Front Output Shaft Spacer Bearing,.80 Thick, Front Output Shaft Spacer Bearing,.85 Thick, Front Output Shaft Shaft Shifter, Declutch Shim, Coral.00 Thick, Upper Shaft Rear Shim, Pink.05 Thick, Upper Shaft Rear Shim, Blue.005 Thick, Upper Shaft Rear Shim, Red.00 Thick, Upper Shaft Rear Shim, Oil Pump Shim, Coral.00 Thick, Intermediate Shaft Front Shim, Pink.05 Thick, Intermediate Shaft Front Shim, Blue.005 Thick, Intermediate Shaft Front Shim, Red.00 Thick, Intermediate Shaft Front Shim, Red.00 Thick, Lower Shaft Front Shim, Blue.005 Thick, Lower Shaft Front Shim, Pink.05 Thick, Lower Shaft Front Shim, Coral.00 Thick, Lower Shaft Front Pin, Dowel, 5/6 x /4 75 Piston, Shift Piston, Shift, Direct Spacer Bearing,.06 Thick, PTO Output Shaft Spacer Bearing,. Thick, PTO Output Shaft Spacer Bearing,.6 Thick, PTO Output Shaft Spacer Bearing,. Thick, PTO Output Shaft Spacer Bearing,.6 Thick, PTO Output Shaft Spacer Bearing,. Thick, PTO Output Shaft Spacer Bearing,.6 Thick, PTO Output Shaft Spacer Bearing,.75 Thick, Lower 48T Gear Spacer Bearing,.70 Thick, Lower 48T Gear Spacer Bearing,.75 Thick, Lower 48T Gear Spacer Bearing,.70 Thick, Lower 48T Gear VP:4/98 SECT 9 PG 4

20 9.0 PARTS LIST CONT D. ITEM PART NO. DESCRIPTION TC-4 TC-4 FOOT QTY QTY NOTE Spacer Bearing,.997 Thick, Lower 66T Gear Spacer Bearing,.99 Thick, Lower 66T Gear Spacer Bearing,.987 Thick, Lower 66T Gear Spacer Bearing,.98 Thick, Lower 66T Gear Plug, Square Head, /4 NPT Plug, Socket Head, Magnetic, /4 NPT Plug, Welch Plug, Speedo, /6-0 Plug, Square Head, /4 NPT Snap Ring Shaft, Shifter, Direct Shaft, Shifter, Neutral Shaft, Front Output Shaft, PTO Output Shaft, Upper Shaft, Intermediate Shaft, Lower Spring, Shifter Shaft, Declutches Spring, Shifter Shaft, Direct Spring, Assembly, Oil Pump O-Ring, Shifter Shaft, Declutches Pump Cartridge Stud, /4-0 x Plate, Declutch Cover Plate, SAE (4) Bolt Hydraulic Pump Mounting Plate, Housing Cover Plate, SAE () Bolt Hydraulic Pump Mounting Plate, Shift Fork Nut, Locking Switch, Shift Indicator, Declutches 9 86 Vent, /8 NPT VP:4/98 SECT 9 PG 5

21 9.0 PARTS LIST CONT D. ITEM PART NO. DESCRIPTION TC-4 TC-4 FOOT QTY QTY NOTE Tube, Sleeve, Speedo Driven Gear Tube, Shift Cylinder Adapters, Declutches Tube, Shift Cylinder Adapters, Direct Tube, Shift Cylinder, Declutches,.75 Long Tube, Shift Cylinder, Direct,.50 Long Tube, Shift Cylinder, Neutral,.06 Long Tube, Shift Cylinder Adapter, Neutral Tube, Spacer, Rear Output Tube, Spacer, Intermediate Shaft Tube, Spacer, Lower Shaft Tube, Spacer, Rear Output Washer, Lock, 5/ Washer, Flat, 7/ Washer, Copper Washer, Shifter Shaft, Direct Washer, Shifter Shaft, Declutches Washer, PTO Output Washer, Input & Rear Output Lockwire Key FOOTNOTES:. Verify correct part number etched on the gear. Caution: if one gear is replaced, others may also need replacement to retain compatibility. Contact Fabco Engineering for technical assistance.. Select one bearing spacer, see section 6.7 of service manual.. Select shim pack, see section 6.5 of service manual. 4. Select shims, see section 6.8 of service manual. 5. Select one bearing spacer, see section 6. of service manual. VP:4/98 SECT 9 PG 6

22 9.0 PARTS LIST CONT D. PARTS NOT ILLUSTRATED TC-4 PART NO. DESCRIPTION QTY TC-4 QTY 66 8 Name Plate Drive Screws, Name Plate LUBRICATION PIPING Suction Line (Sump to Pump) Street Tee, /4 NPT Strainer, Oil 45 Street Elbow, /4 NPT # Hose Assembly 90 Elbow, / NPT x # JIC 90 Street Elbow, / NPT Pressure Line (Pump to Filter) 57 8 Adapter, /8 NPT x # 8 JIC # 8 Hose Assembly Elbow, / NPT x # 8 JIC Pressure Line (Filter to Housing) Elbow, / NPT x # 6 JIC # 6 Hose Assembly Street Elbow, /4 NPT x /8 NPT Pressure Line (Filter to PTO Carrier) Elbow, / NPT x # 6 JIC # 6 Hose Assembly Street Tee, /4 NPT x # 6 JIC Nipple, /4 NPT x / Long Pressure Line (PTO Carrier to Housing) # 6 Hose Assembly Street Elbow, /4 NPT x /8 NPT VP:4/98 SECT 9 PG 7

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