tc-142 pd transfer case parts & service manual
Contents
1. AUTOMOTIVE CORPORATION 142 PD TRANSFER CASE SERVICE MANUAL Fabco Automotive Corporation Livermore Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com TABLE CONTENTS SECTION 142 PD TRANSFER CASE SERVICE 1 444 4 4 442 1 0 save 1 1 PENN 1 2 SPENN TA 1 9 HON eee 2 0 CLEANING S INSPECTION ee 3 0 GENERAL INSTRUC TIONS sje 4 0 5 0 ASSEMBLY __ coved 6 0 intermediate Shall 6 1 UPE SNAN 6 2 LOWE 2200 2556 6 3 Lower Shat MSTA see 6 4 Bearng Ad USUI ae 6 5 SME SNE 6 6 OCICS EEE RE NE RED 6 7 PIMP FIIN 6 8 TORQUE SPECIFICATIONS Se 7 0 eee 8 0 PARTS USETT eesaceans eames 9 0 TOOLS 10 0 Copyright 1990 Automotive Corporation 151 Lawrence Drive Livermore 94551 1 1 INTRODUCTION The Fabco TC 142 PD transfer case with proportional differential is a two speed unit designed for full time all wheel drive vehicles Two proportioning ratios are available 26 74 and2. 6 Page 18 in the Fabco TC 142 Transfer Case Parts and Service Manual 4 Remove the 8 capscrews securing the front output carrier to the lockout housing Pull off the carrier and discard the gasket The front output shaft bearings are installed with a light press fit and therefore some force may be necessary use care not to damage the gasket surface Pull off the remaining bearing cone and remove the clutch gear Remove the C shaped retaining ring from the inner shaft 5 Follow the instructions in Fig 5 1 5 through Fig 5 1 10 in the Fabco 142 Transfer Case Parts and Service Manual 6 Remove the rear output yoke or companion flange 7 Remove the speedometer adapter and pinion gear from the rear output seal carrier Remove the 6 capscrews securing the carrier Remove the carrier and discard the gasket Remove and discard the oil seal from the carrier SECT 2 3 4 5 PG 1 8 Remove the 12 nuts 50 50 model 9 If working on a 50 50 differential remove the 8 capscrews 26 74 model securing the rear out differential housing bolts and nuts Remove the put shaft carrier to the inner differential housing rear housing and the internal differential parts If working on a 26 74 differential remove the 3 planet pin snap rings Remove the planet pins planet gears rollers and spacer from the planet carrier carrier Remove the rear output shaft with its carrier as an assembly Remove
3. 50 50 The 26 74 differential proportions 26 of the input torque to the front axle and 74 to the rear while the 50 50 model divides the torque equally This manual is a supplement and must be used in conjunction with the Fabco TC 142 Transfer Case Parts and Service Manual 1 2 OPERATION For normal operation the transfer case differential control should be in the unlocked position It may be shifted to the locked position when conditions require increased traction The differential control can be locked or unlocked while the vehicle is either stationary or in motion provided the wheels are not slipping Shifts between ranges however must be made while the vehicle is stationary to avoid serious damage to the transfer case The vehicle should not be operated under normal traction conditions with the differential control locked Important When testing any vehicle equipped with a proportional differential transfer case on a chassis dynamometer it is necessary to disconnect the front driveline at the transfer case and operate the unit with the differential control in the locked position These instructions must be followed because the transfer case is not designed for continuous operation with one output shaft turning while the other is stationary Serious damage will occur to the internal differential parts due to excessive speed Also when towing any vehicle equipped with a proportional differential transfer case both the front and rear drivelin
4. 6 74 differential to specification replaced with one of the proper width to obtain the correct end float 16 Remove Tool 866 678 If working on a 50 50 ratio model press the oil seal into the inner side of the rear output shaft carrier The seal must be in stalled backwards i e the end of the seal with the spring must be visible after installation Place a new O ring into the inner side of the rear output shaft carrier SECT 6 PG 6 18 Add the spacer and the speedometer drive gear 6 5 SHAFT AND BEARING END FLOAT to the rear output shaft as shown in Fig 6 4 11 in the Fabco TC 142 Transfer Case Parts and ADJUSTMENT 4 2 2 2 speedometer See Section 6 5 in the Fabco TC 142 Transfer Case 9 9 5 i Parts and Service Manual for the procedure for setting the end float of the upper and intermediate 19 Press the rear output shaft oil seal into its carrier Install the carrier to the rear differential housing shafts carrier with a new gasket Torque the 6 capscrews to specification 6 6 SHIFT SHAFT ASSEMBLY AND AD ps JUSTMENT 2 22 See Section 6 6 in the Fabco TC 142 Transfer Case 2 gt gt Parts and Service Manual 6 7 DECLUTCH ASSEMBLY See Section 6 7 in the Fabco TC 142 Transfer Case 2 7 Parts and Service Manual if the unit is equipped with PG 21 77 6 8 PUM
5. DS AND SHOULD BE WITHIN 10 OF VALUES SHOWN 45 LB FT 600 LB FT 45 LB FT LB FT 40 LB FT 25 LB FT 15 LB FT Per 45 LB FT 777 HERST E 45 85572 DIFFERENTIAL LOCKOUT CYLINDER DETAIL gt LB FT p Vo EBF T 600 LB FT SEE DIFF LOCKOUT SHIFT F LET T CYLINDER DETAIL IR ASS 600 LB FT NN 2222222 Tel SET PEAK lt lt 22 bom E gt TOT LER NER SS 0 ASSIS a 300 LB FT SN KS 8 55 NS 2 EN 45 LB FT 2224 52 10 VA Sm lt 222222222222222222722222222222222 600 LB FT 59 Ts G LB FT TC 142PD 26 74 VEL P 10 0 TOOLING Details of tooling to facilitate servicing the 142 Transfer Case Service tools may be manufactured to these drawings or Fabco Automotive may be contacted for a price and delivery quotation The manufacture of these tools should be carried out by professional machinists and certified welders following typical good workmanship procedures and safe practices SECT 10 PG 1 2 9d 1035 866 0676 DIRECT DRIVE PUSHER TC 142PD 94 Ob 1035 866 0677 FRONT OUTPUT PUSHER TC 142PD L 1035 866 0678 REAR OUTPUT PUSHER TC 142
6. P AND PLUMBING ASSEMBLY See Section 6 8 in the Fabco TC 142 Transfer Case Parts and Service Manual if the unit is equipped with a lubrication pump he 20 Complete the installation of the lower shaft as sembly by following the instructions in Fig 6 4 17 through Fig 6 4 20 in the Fabco TC 142 Transfer Case Parts and Service Manual Note that the end float should have been adjusted prior to Fig 6 4 20 SECT 6 PG 7 Da 241055 ALL TORQUE VALUES ARE FOR DRY THREADS AND SHOULD BE WITHIN 10 OF VALUES SHOWN 45 LB FT 22 2 S g LB FT A 45 LB FT 40 LB FT er Sacer saa aco DIFFERENTIAL LOCKOUT SHIFT CYLINDER DETAIL 7 LB FT 18 45 LB FT 600 LB FT SEE DIFF BAO LOCKOUT SHIFT CYLINDER DETAIL N 35 LB FT 1 5 4 EE 7 41 Soe 2777 SN 555 ST KRIG SYK vs ZZ Sy MS EST KSO Se WIR 2 E r EEE 4725 LAE 222 8222 22 2 522257 SS 1 PSN GS 8 TANTEA 277 SOO 22222222 ID NN 27 me 1 45 LB FT ZNS ED 600 LB FT E 5 L FT TC 142PD 50 50 ENOLIV raa 2 0 0 22 135 TORQUE VALUES ARE DRY THREA
7. PD 9401 1335 TACK WELD 2 PLACES EACH WRENCH KEY 202 at WRENCH KEY 4 REQUIRED MATERAL 4140 STEEL 982 4 PLACES WRENCH WELDMENT F N AFTER WELDING HARDEN Re 40 45 7 32 DRILL 750 SQUARE BROACH 2 THROUGH RI 6 MAX 21 45 GEA 19 oe 03 903 905 3 655 03 030 45 WRENCH BODY 1 REQUIRED MATERAL 4140 STEEL 866 0670 BEARING LOCKNUT WRENCH TC 142PD
8. d and inside the shift collar Heat and install one the bearing spacer replaced with one of the of the front inner shaft bearing cones Slip the proper width to obtain the correct end float bearing spacer onto the shaft 11 Remove Tool 866 677 Press new shaft seal into the lockout carrier and install the front drive yoke or companion flange Torque the locknut to specification SECT 6 PG 3 12 Assemble the differential assembly follows Liberally smear differential components with grease slurry 50 50 Differential a Heat and install the ball bearing assembly onto the rear differential case housing The shielded end must face away from the hous ing ae Ad 17 4 b Insert the thick thrust washer into the front differential case housing The grooves in the washer should be facing rearward Slip a thin flat thrust washer onto one of the differential side gears and place into the differential assembly engaging the splines with the inner shaft c Slip the remaining flat thrust washer onto the remaining differential side gear and place into the rear differential housing d Place differential pinion gear and cal thrust washer on each of the four legs of the differential cross and insert into the rear differential case housing e Joint the two differential case housings together and attach with the 8 bolts and nuts Torque to specification Chec
9. es must be disconnected for the same reasons 1 3 SPECIFICATIONS RATINGS Maximum Input Torque 14 000 Lbs Ft Maximum Input Horsepower 500 HP Maximum Input Speed 2 300 RPM RATIOS Direct 1 1 Underdrive 2 23 1 GEAR TYPE Helical Case Hardened INPUT 2 75 10 Spline REAR AXLE OUTPUT 2 75 10 Spline FRONT AXLE OUTPUT 1 97 10 Spline DROP 16 SHIFT MECHANISM LUBRICATION SYSTEM LUBRICANT OIL CAPACITY WEIGHT Integral Air Cylinder Gear Pump 30 PSI 4 GPM Approximately See Lubrication Section 22 Quarts Est 1 250 Lbs The oil should be filled to the level of the fill plug regardless of the amount used SECT 1 PG 1 2 0 LUBRICATION See Section 2 0 in 142 Transfer Case Parts and Service Manual 3 0 CLEANING AND INSPECTION See Section 3 0 in the Fabco TC 142 Transfer Case Parts and Service Manual 4 0 GENERAL INSTRUCTIONS See Section 4 0 in the Fabco TC 142 Transfer Case Parts and Service Manual 5 0 DISASSEMBLY 1 Follow the instructions in Fig 5 1 1 through Fig 5 1 3 in the Fabco TC 142 Transfer Case Parts and Service Manual Remove the PTO declutch assembly if the unit is so equipped See Fig 5 1 4 2 Remove the front output yoke or companion flange 3 Remove the front lockout shift cylinder parts indicator switch amp pin and the lockout housing cover Cut the lockwire and remove the 2 shift fork clamping screws Withdraw the shift shaft See figures on Sect
10. k to see that the differential assembly rotates freely SEGT 6 PG 4 f Install the 12 long studs into the inner dif 14 Heat and install a bearing cone onto the rear ferential housing carrier output shaft Slip the bearing spacer into posi tion and place into the rear differential housing carrier Heat and install the remaining bearing cone 4 ra 26 74 Differential a Install 8 roller bearing assemblies and 2 spacers into each planet gear Insert into the planetary carrier add a planet pin spacer on each side of the planet gear and slide the planet pin through b Install the planet pin retaining snap rings Check to see that the assembly rotates free ly c Attach the internal gear to the rear output shaft and torque the 12 attaching capscrews to specification 13 Press the bearing cups into the rear output shaft Carrier SECT 6 PG 5 15 Temporarily install Fabco 866 678 with yoke or flange retaining locknut After the as sembly cools to room temperature check the shaft end float with a dial indicator If the end float is not within specification 003 to 008 the shaft must be removed and the bearing spacer 17 Place a new O ring into its groove in the inner differential housing carrier and tap the outer differential housing into place Bring the rear output shaft carrier into position Torque the 12 nuts 50 50 differential or capscrews 2
11. om the opening in the lockout hous ing capscrews to specification 3 Slip the front differential housing 50 50 planet carrier 26 74 onto the rear of the outer shaft Install its attaching locknut and torque to specification 6 If working on a 50 50 differential model skip to Step 7 Otherwise install the round retaining ring in its groove on the rear of the inner shaft shorter splined end Install the sun gear and its snap ring SECT 6 PG 2 7 The inner shaft must be installed from the rear 9 Press the bearing cups into the differential lock Slip the inner shaft into the outer shaft and push out carrier Install the carrier and its gasket to all the way forward Working inside the front the lockout housing Torque the 8 capscrews differential lockout housing install the inner shaft to specification Heat and install the remaining C shaped retaining ring Slide the shift shaft bearing cone Temporarily install Fabco Tool into the fork and add the clamp bolts See Fig 866 677 with the yoke flange retaining locknut 6 7 4 in the Fabco TC 142 Transfer Case Parts and Service Manual Follow the directions in Fig 6 7 5 through Fig 6 7 7 10 After the assembly cools to room temperature check the inner shaft end float with a dial in dicator If the end float is not within specification 8 Slip the differential lockout gear onto the shaft 003 to 008 the carrier must be removed an
12. one See Fig 6 3 5 in the Fabco TC 142 Transfer Case Parts and Service Manual 4 Check and adjust the gear end float as instructed in Fig 6 3 6 in the Fabco TC 142 Transfer Case Parts and Service Manual using Fabco Tool 866 676 instead of 866 649 shown SECT 6 PG 1 5 Install the shaft bearing instructed in Fig 6 3 7 4 The lower shaft end float must be set at this time and Fig 6 3 8 in the Fabco TC 142 Transfer Case Follow the directions in Section 6 5 in the Fabco Parts and Service Manual TC 142 Transfer Case Parts and Service Manual 6 After the bearing cools reverse the shaft in the fixture and slip the clutch collar into place Repeat the procedure with the larger gear using Fabco Tool 866 650 to check and adjust the gear end float See Fig 6 3 9 and Fig 6 3 11 in the Fabco TC 142 Transfer Case Parts and Service Manual Do not install the shaft bearing at this time 6 4 LOWER SHAFT INSTALLATION 1 Follow the directions in Fig 6 4 1 through Fig 6 4 10 in the Fabco TC 142 Transfer Case Parts and Service Manual 2 Press the bearing cup into the inner differential housing carrier Install the carrier and a new gasket to the main housing Torque the 11 5 Insert the differential lockout collar together with its shift fork into the front lockout housing Be sure to observe the orientation of these parts The longer end on the collar must face inward and the fork must have its clamp bolt heads accessible fr
13. the outer dif ferential housing and discard the O rings Remove the 12 studs 50 50 SECT 5 PG 2 10 Remove the inner shaft rearward Remove the 12 Continue disassembly by following Fig 5 1 12 front differential housing or planet carrier retain through Fig 5 1 19 in the Fabco TC 142 Transfer ing nut with Fabco Tool 866 670 or equivalent Case Parts and Service Manual Remove the housing or carrier 13 Tap or press the rear output shaft through the rear output shaft carrier If working on a 50 50 model remove and discard oil seal Mss 11 Remove the 6 capscrews securing the front lockout housing to the main housing and remove the housing 6 0 ASSEMBLY See Section 6 0 in the Fabco TC 142 Transfer Case Parts and Service Manual 6 1 INTERMEDIATE SHAFT See Section 6 1 in the Fabco TC 142 Transfer Case Parts and Service Manual 6 2 UPPER SHAFT See Section 6 2 in the Fabco TC 142 Transfer Case Parts and Service Manual 6 3 LOWER SHAFT SUB ASSEMBLY 1 Press the bearing cups into both lower gears 2 Place the end of the outer lower shaft with the smaller diameter threads into the assembly stand similar to Fig 6 3 1 in the Fabco TC 142 Transfer Case Parts and Service Manual 3 Slip a gear bearing cone onto the shaft See Fig 6 3 3 in the Fabco TC 142 Transfer Case Parts and Service Manual Install the smaller gear the bearing spacer and the second bearing c
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