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2 VIII. PARTS MANUAL TC-35 PARTS MANUAL INDEX SECTION THROUGH ASSEMBLED SHAFTS PM2 EXPLODED VIEWS WITH PARTS LISTS Front Output Shaft Rear Output Shaft Intermediate Shaft Input Shaft Air Shift H-N & H-N-U Manual H-N-U Shift Air Operated Front Drive Declutch Manual Front Drive Declutch PTO Air Operated PTO Shift Manual PTO Shift Oil Lines and Fittings PTO HOUSING, COVER AND MISCELLANEOUS PARTS PM3 PM4 PM5 PM6 PM7 PM9 PM10 PM11 PM12 PM13 PM14 PM15 PM16 FABCO AUTOMOTIVE CORP. TC-35 Service & Parts Manual PM1

3 TC-35 Shafts, Gears, Bearings, Spacers, Seals Carriers and Caps

4 ITEM PART NO. DESCRIPTION Nut, Nylon Lock Washer, Capscrew, Seal Carrier, Oil Seal Gasket Bearing Shaft, Front Output Clutch ITEM PART NO. DESCRIPTION Bearing Gear Spacer Ring Spacer Ring Bearing Shim, Coral Shim, Pink Shim, Blue Cover, Fos Rear, Ros Front

5 ITEM PART NO. DESCRIPTION Nut, Nylon Lock Washer, Capscrew, Shim, Coral Shim, Pink Shim, Blue Cover, Ros Front Nut, 1-20 Nylon Lock Ring, Split Washer, I.D Bearing Cup ITEM PART NO DESCRIPTION Bearing Cone Shaft, Rear Output Gear, Rear Output Washer, Bearing Spacer Bearing Cone Bearing Cup Ring, Spacer Gasket, Rear Output Carrier Carrier, Rear Output Shaft (Case w/p. Brake) Carrier, Rear Output Shaft (Case w/o P. Brake) Seal, Rear Output Shaft REAR OUTPUT SHAFT

6 ITEM A PART NO. DESCRIPTION Nut, 1¼-18 Nylon Lock Capscrew, Connector, Speedo Cap, Plastic Gear, Speedo Driven Vent Cap, Speedo Gasket Nut, 1-20 Nylon Lock Gear, Speedo Drive Ring, Speedo Drive Gear Spacer Washer, Brg. Spacer ITEM PART NO. DESCRIPTION Bearing Gear, Underdrive 41T Clutch Gear, Intermediate Shaft Shaft, Intermediate Ring, Split Gear, 34T Washer, Intermediate Shaft Spacer Bearing, Roller (Complete) Washer, 1¼ ID Gasket, Intermediate Shaft Rear Cap, Intermediate Shaft Rear

7 ITEM PART NO. DESCRIPTION Nut, 1¼-18 Nylon Lock Washer, I.D Capscrew, (Cases w/pto) (Cases w/o PTO) Seal Carrier, Oil Seal (Cases w/o PTO) Carrier w/oil Line Connection (Cases w/pto) Gasket Clutch Bearing Spacer Ring ITEM PART NO. DESCRIPTION Shim, Coral Shim, Pink Shim, Blue Bearing Gear 19T Split Ring Shaft, Input Gear, 35T w/lnt. Clutch Washer Bearing Cap, Input Shaft Rear (w/o PTO) INPUT SHAFT

9 H-N-U Air Shift H-U Air 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 Spring, Air Shift Return Adaptor, Air Shift Cyl Set Screw Lockwire Gasket, Shift Shaft Cap Cap, Shift Shaft Capscrew, ¼-20 x ½ Fork, Direct Drive Shift Fork, Under Drive Shift Shaft, H-N-U Air Shift Tube, Shift cyl Nut, Special Set Screw, Allan Head Adaptor, Piggyback Cyl Shaft, Piggyback Cyl Tube, Piggyback Cyl. & PTO Cyl Stud, Piggyback Cyl. Mtg Nut, ¼-28 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 Spring, Air Shift Return Adaptor, Air Shift Cyl Set Screw Lockwire Gasket, Shift Shaft Cap Cap, Shift Shaft Capscrew ¼-20 x ½ Fork, Direct Drive Shift Fork, Under Drive Shift Shaft H-N-U Air Shift Tube, Shift Cyl Capscrew, Air Shift Cyl. ½-20 x 4¾

10 ITEM PART NO. DESCRIPTION Set Screw Lockwire Gasket, Shift Shaft Cap Cap, Shift Shaft Capscrew, ¼-20 x ½ Capscrew, ¼-20 x Seal, Shift Shaft ITEM PART NO. DESCRIPTION Carrier, Seal Set Screw, Nylock Spring, Detent Ball, Detent Fork, Direct Drive Shift Fork, Under Drive Shift Shaft, H-N-U Mechanical Shift

11 ITEM PART NO. DESCRIPTION Plastic Plug Cap, Air Shift Cyl O-Ring, Air Shift Cap & Adaptor Tube, Air Shift Capscrew, Shift Cyl. Mtg Nut, Shift Piston Washer, Shift Piston O-Ring, Shift Piston Piston, Shift Felt Ring, Shift Piston O-Ring, Shift Shaft Shaft, Air Front Drive Shift Ring, Nylon Bump ITEM PART NO. DESCRIPTION Spring, Air Shift Return Adaptor, Air Shift Cyl Fork, Front Drive Shift Set Screw Lockwire Plastic Plug Switch, Indicator Washer, Copper Dowel, Switch Operating Gasket, Shift Shaft Cap Cap, Shift Shaft Capscrew, ¼-20 x ½ AIR OPERATED FRONT DRIVE DECLUTCH

12 ITEM PART NO DESCRIPTION Fork, Front Drive Shift Set Screw Lockwire Plastic Plug Switch, Indicator Washer, Copper Dowel, Switch Operating Gasket, Shift Shaft Cap Cap, Shift Shaft ITEM PART NO. DESCRIPTION Capscrew, ¼-20 x ½ Capscrew, ¼-20 x Seal, Shift Shaft Carrier, Seal Shaft, Shift Set Screw, Nylock Spring, Detent Ball, Detent Tube, Front Drive Limit

13 ITEM PART NO. DESCRIPTION Fork, PTO Shaft Collar, Sliding Clutch Housing, Main PTO Capscrew, x 4½ (12) Point Bearing Cup Bearing Cone Shaft, PTO Coral Shim Pink Shim Blue Shim Carrier, Bearing & Seal Capscrew, Seal, PTO Output Tube, PTO Output (Temporary) Washer, PTO Output Yoke Nut, PTO Output Yoke ITEM PART NO DESCRIPTION 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, Plastic PTO

14 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. ½-20 x 4¾ 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.

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

16 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

17 Parts not designated on the drawing. Used on all cases unless otherwise specified. ITEM PART NO. DESCRIPTION Housing, Main Case Cover, Main Case Gasket, Main Cover Bracket, Case Lifting Capscrew, Cover Mtg. x Capscrew, Cover Mtg. x 1¼ Washer, Cover Mtg. Screw Lock Label, Serial Plate Screw, Serial Plate Mtg. Drive Plug, ¼ NPT Magnetic Drain Plug, ¾ NPT Fill Plug, ½ NPT Return Line Hole 1 (w/o PTO) PM16

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

Telephone:(925) Fax:(925) Lawrence Drive, Livermore, CA Telephone:(95)5-9500 Fax:(95)5-950 5 Lawrence Drive, Livermore, CA 955 www.fabcoautomotive.com Table of Contents This manual covers single and dual rear output versions of the TC- two-speed transfer case