TC-237 Parts & Service Manual - Fabco Automotive Corporation
Contents
1. 10 000 15 000 Miles Off Highway Service Logging dirt moving mining and associated 5 500 750 Hours The recommended oil change and inspection periods are based on the average use and operating conditions that the unit may encounter It is suggested that the individual owner make a periodic lab analysis of the lubricant to determine contamination based the units specific operating conditions With this data the oil change and inspection periods can be better determined DRAINING THE OIL Draining is best accomplished after the vehicle has been operated briefly allowing the oil to become warm and flow more freely Remove both drain and fill plugs Allow the housing to empty completely Before the unit is refilled it should be thoroughly flushed with clean flushing oil or kerosene REFILLING THE OIL If the transfer case has been removed from the vehicle for service it is best to refill the oil after the unit has been reinstalled into the vehicle Clean and replace the drain plug and fill the transfer case with the appropriate oil with the vehicle on level ground Fill the transfer case to the level of the fill plug The plug should be installed only after the oil level has stabilized For each transfer case the oil capacity will vary somewhat depending on the model and the inclination of the unit therefore always fill to the level of the fill plug Do not2. Automotive Corporation 237 TRANSFER CASE SERVICE MANUAL Fabco Automotive Corporation Livermore Ph 925 454 9500 1 800 967 8838 FAX 925 454 9501 www fabcoautomotive com TABLE OF CONTENTS Introduction and Specifications 3 Front View 4 Rear View 5 Lubrication Types and Inspection 6 Cleaning and Inspection End float Explanation 8 General Instructions Assembly Precautions 9 Removal and Installation 10 General Disassembly 11 Disassembly of the Sub assemblies 17 Input Shaft Assembly 19 Intermediate Shaft Assembly 21 Rear output Shaft Assembly 22 Front output Shaft Assembly 22 General Assembly 24 Torque Specifications 32 Parts Identification 33 Parts Listings 35 Tooling 40 Copyright 1998 Fabco Automotive Corporation 151 Lawrence Drive Livermore CA 94551 237 TRANSFER CASE e INTRODUCTION The Fabco TC 237 two speed transfer case is designed for use in all wheel drive vehicles The transfer case provides drive to the front axle s and can be used in any configuration of rear driven axles The front drive axle can be engaged at any vehicle speed provided the rear wheels are not spinning however the vehicle must be stationary before the shift can be made between high and low ranges otherwise serious damage may occur The shifting between ranges and the engagement of front drive and power take off clutches is accomplished by air operated cylinders e SPECIFICATIONS The TC 237 transfer case is a t
3. 18 ASSEMBLY Make sure all parts are clean dry and lint free Any traces of storage wax or paper should be removed Leave bearings and cups in their wrappers until ready to use All threaded holes and fasteners should be cleaned with solvent to ensure that locking compound adheres properly Unless indicated otherwise part mating surfaces should be given a light coating of lubricant Lubriplate is an acceptable grease A substitute may be utilized consisting of a mixture of chassis grease and 30W engine oil The mix should be thin enough to apply with a small brush NOTE WHEN A PART IS ASSEMBLED WITH A PRESS FIT IT IS RECOMMENDED THAT THE PART HEATED PRIOR TO INSTALLATION IN A SUITABLE OVEN AT A TEMPERATURE NO GREATER THAN 300 INPUT SHAFT ASSEMBLEY 1 Slide retaining ring onto input shaft using a press and plate until it is seated in the groove See Fig 32 Rear output shaft is shown method for input shaft similar Groove Press 1 Retaining Ring Retaining Ring coc 4 Install the heated front bearing onto input shaft then turn the shaft over and install the clutch gear with Fig 32 the groove down and the teeth up See Fig 34 2 Press the bearing cups into the direct drive gear Place one in each side 3 Install the underdrive gear onto the threaded eh ji Clutch end of the shaft Check to see that the retaining ring is
4. see page 8 If the endplay is not within the specification the front declutch housing will need to be removed and shim gaskets of the proper thickness used See Fig 75 Fig 75 Place new orings onto all shift cylinder components that were disassembled Coat all o rings with Lubriplate or similar Place the front declutch shift fork and collar into housing See Fig 76 Declutch Collar Fig 76 34 Install the shift shaft into the housing and declutch fork Align the notches in the shaft with the holes in the fork Install bolts Torque to spec and lock wire as shown See Fig 77 Fig 77 35 Install the o ring onto the shoulder of shift shaft 36 Install the shift cylinder adapter into the case See Fig 78 Shift Cylinder Adapter 37 Install the declutch shift spring nylon stop ring and shift piston onto shift shaft Use Loctite 272 on threads and torque piston retaining nut to spec See Fig 79 Hylon Stop 81 Piston AY Declutch Spring Fig 79 38 39 40 41 Install an oil soaked felt wiper into the large groove on the shift piston and install shift cylinder See Fig 80 Fig 80 Install the shift cylinder cap using Loctite 242 on the threads Torque to spec See Fig 81 Shift Cylinder Fig 81 Install the front drive engagement indicator switch pin 3 such that the rounded end of the pin is facing the shift shaft Install the indicator switch
5. 1 using one copper washer 2 Note it may be necessary to use two washers for proper switch operation See Fig 82 42 43 44 Check for continuity across the leads of the 45 Place the range shift forks into the housing with the sensor with a continuity tester The tester should flat sides facing each other See Fig 86 indicate a closed circuit with air pressure applied to the air shift cylinder See Fig 83 Fig 86 46 Place a new oring on the shoulder of the shaft and Fig 83 install the piston to the shaft using 272 Loctite on Install front output shaft into declutch housing the retaining nut threads Torque to spec See Fig using a new gasket Align bearing oil drain with the bottom of the case Apply Loctite 272 to bolt threads and torque to spec See Fig 84 Fig 87 47 Install the shift cylinder adapter to the housing Fig 84 48 Insert the range shift shaft containing the shaft Install front declutch cover plate using Loctite nylon stop ring and range shift spring into the 242 on bolt threads Torque to spec See Fig housing passing it through the range shift forks See 85 Fig 88 Range Shift Spring 30 49 Align the grooves the shift shaft with the holes in the shift forks Install bolts with 272 Loctite Torque to spec and lock wire See Fig 89 Loc
6. bearing on the shaft Install the input shaft yoke and toque the locknut to spec 15 Temporarily bolt the shift shaft cap on to the front of the housing using one bolt This will provide a base for a dial indicator See Fig 59 25 Shift Shaft Cap Fig 59 16 Lightly tap the shaft to rear of the case to seat the bearing See Fig 60 Fig 60 17 Measure the input shaft end float using a dial indicator placed on the shift shaft cap End float should be 003 in tight to 003 in loose page 8 If the end float is not within the specifications the input shaft rear cap will need to be removed and shim gaskets of a different thickness used See Fig 61 Fig 61 18 Install the rear output front bearing cup into the housing See Fig 62 Fig 62 19 Install all declutch housing gasket shims that were removed during disassembly Install the declutch housing to the main housing using Loctite 272 Torque the bolts to spec in a criss cross pattern See Fig 63 Fig 63 20 Install rear output shaft into housing from the rear See Fig 64 21 Install intermediate shaft assembly into housing See Fig 65 A gt Rear Output 22 Install direct drive gear onto the intermediate and rear output shafts until the retaining rings are fully seated into the grooves on both of the direct drive gears See Fig 66 Fig 66 23 Install heated bearings onto the intermediate and
7. end float should be 000 to 002 inches loose see page 8 If the end float is not within the specifications the gear and rear bearing will need to be removed and a bearing spacer of a different thickness used Fig 39 7 Remove the bearing locknut and set up spacer 4 Place a heated bearing 1 onto the large end of the shaft followed by the spacer 2 underdrive 8 Install a heated bearing 1 onto the shaft Install the gear 3 and rear bearing 4 in the order shown bearing locknut 2 using 290 Loctite on the threads in figure 40 and torque to spec See Fig 42 1 Fig 42 Fig 40 9 This completes the intermediate shaft assembly 21 1 REAR OUTPUT SHAFT 2 Install the snap ring and front output shaft gear onto the front output shaft 1 Install the retaining ring into the groove on shaft See Fig 45 See Fig 32 2 Install a heated bearing onto the shaft so that it is seated against the shoulder See Fig 43 3 Install the front declutch gear so that the speedometer tone ring is facing the bearing See Fig 43 Bearing LI 45 3 Install a heated bearing 1 bearing spacer 2 front output carrier 3 and heated outer bea
8. fully seated in the groove the underside of the gear See Fig 33 Underdrive Gear L Fig 34 19 5 Install the remaining parts onto the shaft in the order shown in Fig 35 amp 36 5 Bearing 6 Bearing Spacer 7 Direct drive Gear 8 Bearing Fig 35 Direct Drive Gear 6 Place the end float set up tool onto the shaft and install the rear bearing lock nut using special socket 866 0687 002 Torque to spec See Fig 37 Special Tool 866 0687 002 End Float Set up Tool Fig 37 7 Check gear end float using a dial indicator as shown below Clearance should be 000 to 002 inches loose If the end float is not within the specified limits see page 8 another bearing spacer 6 Fig 35 will need to be selected See Fig 38 8 Remove the bearing lock nut and spacer 9 This completes the assembly of the input shaft 20 INTERMEDIATE SHAFT ASSEMBLY 5 Install the end float set up tool and bearing locknut onto the shaft and torque to spec Measure the end 1 Press the retaining ring onto the shaft float using a dial indicator as shown in figure 41 See Fig 32 Place the indicator stand base on the gear face 2 Press bearing cups into the under drive gear Fig 41 3 Place the clutch gear onto the shaft with the endort retaining ring and the small 25 Bearing ee Fig 39 Set up Tool 2 2 Large End 6 Gear
9. intermediate shaft has been removed from the housing the rear support bearing and the direct drive gear will have been removed from the shaft 2 Heat the bearing locknut slightly to soften locking compound and remove using special tool 866 0687 002 3 Press the under drive gear and all bearings off of the shaft as shown See Fig 28 PRESS I E 2 NN 6 4 g 72 rj Fig 28 REAR OUTPUT SHAFT 1 Heat the bearing locknut slightly to soften locking compound and remove using special tool 866 0687 004 2 Remove front declutch gear along with the speedometer tone ring 3 Remove front support bearing as shown See Fig 29 PRESS L FEMOVE Fig 29 4 Invert the shaft to remove direct drive gear and rear support bearing See Fig 30 PRESS Fig 30 5 This completes the disassembly of the rear output shaft FRONT OUTPUT SHAFT 1 Remove front output carrier both bearings and front output shaft gear as shown See Fig 31 PRESS 1 Fig 31 2 This completes the disassembly of the front output shaft assembly
10. overfill Inspect for leaks OPERATING TEMPERATURE The operating temperature of the transfer case should not exceed 250 F 120 C Extensive operation at temperatures exceeding 250 F will result in rapid breakdown of the oil and may shorten the transfer case life The following conditions may contribute to excessive oil temperature 1 A vehicle remaining stationary for extended periods while operating the power take off 2 A vehicle which is used in tropical or desert conditions 3 A vehicle where extended bodywork or an accumulation of dirt and plant material may shield the case from air ventilation and circulation 4 A vehicle that is operated for extended distances at high speed with the main transmission in overdrive CLEANING AND INSPECTION e CLEANING Steam may be used for external cleaning of completely assembled units Care must be taken to ensure that water is kept out of the assembly by sealing breather caps and other openings The transfer case parts that are too large to conveniently clean with solvents may be immersed in a hot solution tank containing a mild alkaline solution Aluminum parts such as the carriers caps declutch housings air shift cylinder components and aluminum case housings must never be cleaned in any type of alkaline solution Parts cleaned in hot solution tank must be rinsed thoroughly to prevent damage by traces of alkaline material Parts with ground or polished sur
11. 104B specifications 2 Mineral Gear Oil Temperature Grade Above 10 F SAE 90 Below 10 F SAE 80 Must be inhibited against corrosion oxidation and foam e OFF HIGHWAY amp MINING EQUIPMENT 1 Heavy Duty Engine Oil Temperature Grade Above 10 F SAE 50 Below 10 F SAE 30 Be sure to specify heavy duty type meeting MIL L 2104B specifications 2 Special Recommendation For extreme cold weather where temperature is consistently below OF use SAE 20W heavy duty engine meeting MIL L 2104B specifications NOTE EXTREME PRESSURE EP OILS ARE NO LONGER RECOMMENDED FOR USE IN FABCO TRANSFER CASES UNDER CERTAIN OPERATING CONDITIONS THESE OILS MIGHT FORM CARBON DEPOSITS ON GEARS SHAFTS AND BEARINGS INSPECTION The oil is to be maintained at the level of the fill plug at all times Check at the following intervals Highway Service 1 000 Miles Off Highway Service 40 Hours With every oil change the shift cylinder air lines and valves should be inspected for leaks and possible malfunctioning Low pressure conditions can cause partial clutch engagement which may result in premature wear or damage OIL CHANGE The transfer case lubricant should be changed on all new transfer cases after the first 3 000 to 5 000 miles on highway or the first 40 hours off highway thereafter oil changes should be done at the following intervals On Highway Service
12. 81141 772 59113 006 AS 5 SSH zA NY a 581142 591 15 02 gt gt gt I A LZ y WAS ws 22 amp ASS 97 13 006 gt 91 L 9V H3AOO ONISNOH Pg an 591 14 00 68114 92 HOLIMS HOLVOIONI SANG IM094 891 L 06 LAN ONINIVLSY NOLSId L4IHS 91 L SZ 51109 141 5 SONVY 597 14 SP 1108 MHOJ IM094 891 L40 22222777 gt 27777777772222222 2177 NMOHS LON TOOLS Details of tooling to facilitate the servicing of the Fabco TC 237 Transfer Case Service tools may be manufactured to these drawings or Fabco Automotive may be contacted for price and availability The manufacture of these tools should be carried out by professional machinists and certified welders following typical and good workmanship procedures and safe practices 39 52570 8 30MVVI 2 SIN 100 890 998 575 62 109 721841 8 55441 595 8 596 2C 215 I9 C 00 890 998 200 0091998 6240 889 OIN 200 890 998 C75 so z Joge z ISES eas 019 878 18C5 86 5 lt I 9 200 890 998 ON 1001 ON LUV 3215 Cr tT HI oO 4 3 Oo OB G
13. LERIES AND PASSAGES ALL BEADS MUST BE KEPT SMALLER THAN 1 8 INCH DIAMETER REMOVAL amp INSTALLATION REMOVAL Remove fill and lower drain plugs and drain gear lubricant Disconnect wires leading to indicator light switch and temperature sensor if used Disconnect and tag shift cylinder air lines Disconnect speedometer cable Disconnect drivelines at flanges or yokes Position a transmission jack of suitable capacity beneath the transfer case The transfer case must be seated on jack in a safe and firm position Disconnect transfer case mountings at the rubber shock insulators Since mounting designs vary consult the vehicle service manual After making sure that all mountings and connections to the transfer disconnected lower the transfer case gradually to the floor It is imperative that the transfer case is ALWAYS safely positioned on the transmission jack to safeguard the transfer case from falling off the jack Remove the transfer case from beneath the vehicle It may be necessary to jack the truck up to allow room to remove transfer case 10 NOTES 10 INSTALLATION INTO THE VEHICLE Place the transfer case onto a transmission jack Position the transmission jack underneath the vehicle Some vehicles may require that one side be jacked up in order to achieve sufficient clearance to place the transfer case between the frame rails Raise the transmission jack to properly loca
14. S VO ON SUV 1936 LANYOOT ONIHY3H 01 X Jd 9 1 j i 1 1 I3A 931 V 92 3 5 6 g 7 s dAVLS UM PEE C X O X Sl 1 H I SE i t 177140 91 81 350 je Oz 40 OLA lWlealya pce ee 9100 HV3H 195 60 XC 61 tH ra AM VI 150 B x 1 6 gt gt 994 90 20 11 amp 99 S 41 2 14315 0 d3AldUd 2 88079 C 56176 L 42 19315 0 9MI8V ONISV3U 104110 1M09 082 000 5 SAV 2 OSt HI9N31 THN 0 43 13315 0 IIII 08 0 998 00 00 52 VI z
15. ase A J ME Fig 13 18 Remove the rear bearing lock nut from the intermediate shaft using the special socket 866 0687 002 See Fig 14 Front Declutch Collar Note It may be necessary to warm the nut slightly to soften the locking compound applied to the threads 13 intermediate Shaft Input Seal Camer Fig 14 Fig 16 19 Remove the input shaft rear cap from housing See Fig 15 22 Using a piece of brass or other soft material lightly tap the input shaft toward the front of the case to drive out the front bearing cup See Figs 17 and 18 Fig 15 20 Remove the bearing locknut from the rear of the input shaft using the special socket 866 0687 002 It may be helpful to engage both the high and low range drive clutches to lock the input and intermediate shafts together Note It may be necessary to warm the nut slightly to soften the locking compound applied to the threads 21 Remove the input yoke and seal carrier from the housing See Fig 16 14 23 Slide the input shaft to the front of the case using a piece of wood in between the gear and the case to support the direct drive gear See Fig 19 Fig 21 26 Slide the intermediate shaft toward the rear of the housing as far as possible to facilitate the removal of the direct drive gear See Fig 22 24 Using a large brass drift and a hammer drive the input shaft forward forcing the di
16. ee Fig 50 Special Tool 6 Remove the directdrive gear from the input shaft and place it into the housing such that the shaft may pass through it See Fig 53 Fig 50 Install a new rear output seal into the rear housing Install the intermediate shaft front bearing cup into main housing using special tool 866 0780 See Fig 51 Direct drive Gear 24 7 Install the input shaft 1 into the housing while 10 Install the input shaft seal carrier to the case using a passing it through the direct drive gear 2 Re new gasket Use Loctite 272 on bolt threads and install the rear bearing 3 torque to spec in a criss cross pattern See Fig 54 11 Install the rearmost input shaft support bearing hot and bearing locknut using Loctite 290 on the threads Torque to spec 12 Install the rear outer bearing cup into housing followed by the bearing cup spacer See Fig 57 d I X Fig 54 8 Install the front bearing cup into housing leaving it protruding slightly See Fig 55 Fig 57 13 Install the gasket shims that were removed during disassembly and install the input shaft rear cap Use Loctite 272 on bolt threads and torque to spec Front Bearing See Fig 58 Cup Fig 55 9 Install a new seal into input shaft seal carrier using an arbor press or similar as shown See Fig 56 14 Install the input shaft washer in front of the forward most
17. ements given in this service manual refer to the specifications as tight or loose While a loose measurement can be taken directly as read from a dial indicator a tight one cannot Tight end float measurements can only obtained mathematically through measurement that was previously loose Ex f an intermediate shaft end float measurement of 005 inches loose is found a 002 inches tight end float measurement can be obtained by removing 007 inches of shims from behind the bearing cup If the previous example s measurement were taken after the shims were removed it would have shown an end float measurement d 000 inches which is incorrect Therefore if a measurement of 000 inches is obtained it is best to disassemble the part add a shim of minimal thickness and re measure Using this method will alleviate X end float measurements that may be overly tight GENERAL INSTRUCTIONS SAFETY The servicing and maintenance of components from any automotive vehicle present possible hazards every endeavor should be made to minimize the risks taken to successfully complete the task For your protection we offer these warnings and suggestions 1 When working on around or under the vehicle the parking brake should be securely applied and all wheels should be blocked to prevent wheel movement Do not rely on the vehicle being in gear with a dead engine to prevent movement All work should be performed on a flat l
18. evel surface free of loose material 2 When working under a vehicle it should be raised and supported with the appropriate frame stands or very secure blocking AN WARNING NEVER WORK UNDER A VEHICLE WHILE SUPPORTED ONLY ON A FLOOR JACK OR HOIST 3 Be sure any lifting equipment has adequate capacity to raise the vehicle or component being lifted This includes hydraulic floor jacks crane type hoists transmission jacks and axle support dollies etc The weight of Fabco components is given in the front of the applicable service manual 4 Caution must be exercised when cleaning the component or underside of the vehicle Compressed air should not be used to blow dirt away as any harmful contaminant material on the bottom of the vehicle will be spread around the work area Appropriate solvents and cleaning solutions can be used in accordance with their labeling instructions or by referring to the Material Safety Data sheet MSDS that is available for each cleaner Approved protective eyewear gloves masks and clothing should always be worn ASSEMBLY PRECAUTIONS 1 Read the instructions completely before starting reassembly Refer b the appropriate exploded view in the parts manual 2 parts must be clean The gasket surfaces must be free of old gasket material Do not reuse old gaskets 3 Bearing cup bores shaft splines and bearing mounting surfaces should be coated with Lubriplate or equivalent Th
19. faces such as bearings gears shafts and oil pump components should be cleaned with emulsion cleaners or petroleum solvents alkaline solution may damage the machined surfaces and such cleaning methods should be avoided DRYING AND CORROSION INHIBITION Dry parts with compressed air or clean soft shop towels should be used to dry parts after cleaning Bearings should never be spun dry with compressed air Dried parts should be immediately coated with a light oil or corrosion inhibitor to prevent corrosion damage Parts to be stored should also be wrapped in heavy waxed paper or plastic bags and kept dust free e INSPECTION Prior to reassembly parts that are to be reused must be carefully inspected for signs of wear or damage Replacement of such parts can prevent costly downtime at a future date All bearing surfaces including roller bearing cups and cones should be examined for pitting wear or overheating Gears may also show pits as well as scoring and broken teeth Shafts may be nicked or marred or have damaged threads Parts that show any sign of damage should be repaired or replaced Inspect the internal parts of the oil pump if equipped for scoring Any damaged parts should be replaced Check all shift forks and grooves in sliding clutches for wear or discoloration due to heat Check the engaging teeth for a partial engagement wear pattern END FLOAT MEASUREMENTS End float measur
20. is is necessary to reduce the possibility of galling 4 All used oil seals must be replaced and the new oil seals should be coated with Loctite 601 or equivalent on their outer diameter prior to being installed in their bores The sealing lips should be coated with Lubriplate or the equivalent to provide initial lubrication 5 Unless otherwise specified any external cap screw not installed in a blind hole should have its threads coated with Permatex FormA Gasket 2 or an equivalent non hardening sealer to prevent an leak 6 All threaded fasteners should be tightened to the torque specified in the torque chart 7 Any sharp edges on the seal diameter of the universal joint yoke or companion flanges should be removed with emery cloth and should be coated with Lubriplate or the equivalent on the seal operating area prior to installation 8 In many of the procedures when a part is assembled with a press fit it is recommended that the part be heated prior to installation The part should be placed in an oven and heated to no more than 300 F Excessive heat may change the metallurgical properties of the Heated components should be allowed to cool to room temperature before end float measurements are made N CAUTION ALTHOUGH FABCO DOES NOT RECOMMEND ITS USE IN TRANSFER CASES IF FORMED IN PLACE GASKET IS USED FOR REPAIRS EXTREME CAUTION MUST BE EXERCISED TO PREVENT THE COMPOUND FROM ENTERING BEARINGS OIL GAL
21. k wire Fig 89 50 Install an oil soaked felt wiper in the large groove on range shift piston and slide the cylinder onto the piston See Fig 90 Fig 90 51 Install the shift cylinder cap onto cylinder using Loctite 242 on the bolt threads Torque to spec See Fig 91 Fig 91 52 Install the shift shaft cover plate using Loctite 242 on the bolt threads See Fig 92 31 Shift Shaft Cover Plate Fig 92 53 Install all drain and fill plugs and or speed and temperature sensors 54 Install the housing cover plate using split lock washers and Loctite 272 on the threads Torque to spec See Fig 93 Fig 93 55 This completes the transfer case main assembly TORQUE SPECIFICATIONS S IVNISIHO SV AWVS ASN 83 V Id 5971 14 06 S1709 SZ I 8 390V95 SHOW Id Sg T 14 07 SL108 SZ I 9 390V95 591 13 06 591 13 009 ab DL ss y m 72 2 20 29 7 7 N Ne 22272 lt 2223 ML SWZ 2277 WSS gt ve m 11 11 j 22 CA A 23 ZZ mm 422 591 15 00 IN AES 222223 N ssi a PAL 2 FASS iz 4 fn 1 E M E mm 22 68714 00 2 277 97139 3 SIN INE 22 24 6
22. lightly tap shift forks toward front of case to free them from the shift shaft See Fig 5 Shift Cylinder Adapter Fig 7 9 Remove shift forks from case 10 Remove the front declutch cover plate See Fig 8 Fig 5 7 Lightly file the shift shaft to remove the indentations left by the set screws This will prevent damage to the case and make the forks and shaft easier to remove See Fig 6 11 Remove the front declutch shift cylinder bolts then remove the cap and cylinder 12 If necessary remove the declutch shift piston from the shift shaft See Fig 9 8 Remove the shift shaft along with the piston spring and nylon stop ring Similar to Fig 9 If needed the shift cylinder adapter may also be removed from the case See Fig 7 12 13 Remove and discard the safety wire from the 16 Remove the yoke and rear output shaft spacer from front declutch shift fork bolts Be careful not to the rear output shaft drop the wire into the housing See Fig 12 14 Remove the declutch shift fork bolts followed by the front output carrier bolts Remove the front output carrier from the housing See Fig 10 Front Declutch ee Housing Front Output Carrier 17 Remove the rear carrier See Fig 13 Fig 12 Fig 10 15 Remove the shift shaft from housing followed by the declutch fork and collar See Fig 11 Note It is not necessary to remove the declutch housing to disassemble the c
23. rear output shafts 24 Install a washer locknut onto the intermediate shaft using Loctite 290 on the threads Torque to spec See Fig 67 TA 25 Slide the spacer onto rear output shaft See Fig 68 26 Install a gasket and the rear housing onto the case Use Loctite 272 on all bolts and torque to spec See Fig 69 SOT mm Rear Carrier Fig 69 27 II not already completed Drive a new seal into the rear housing using special tool 866 0782 See Fig 70 Special Tool 666 0762 Fig 70 27 28 Check the intermediate shaft end float using dial indicator through the vent hole in the front of the case Pry the shaft toward the rear of the case to seat the bearing Zero the indicator and then pry the shaft forward The endplay should be 003 in tight to 003 in loose see page 8 If the endplay is not within specification the rear carrier and intermediate shaft rear bearing cup will need to be removed and shims of the proper thickness inserted behind the bearing cup See Figs 71 amp 72 Fig 72 29 Install the rear output yoke onto the shaft and torque to spec See Fig 73 30 31 32 33 Tap rear output shaft toward the front of the case to seat the bearing against the front declutch housing See Fig 74 Fig 74 Measure the rear output shaft endplay using a dial indicator The endplay should be 003 inches tight to 003 inches loose
24. rect drive gear and rear bearing off the shaft Be careful not to let the input shaft fall to the floor See Fig 20 Fig 22 27 Using a gear puller or similar tool remove the direct drive gear from the intermediate shaft See Fig 23 Fig 20 25 Remove bearing direct drive gear and clutch gear while sliding the input shaft out the front of the case See Fig 21 15 28 Remove intermediate shaft from the housing See Fig 24 Fig 24 29 Remove the rear output shaft from the case by sliding it through the rear carrier opening See Fig 25 Fig 25 30 This completes the main disassembly of the transfer case 16 DISSASSEMBLY OF THE SUB ASSEMBLIES INPUT SHAFT 1 After the input shaft has been removed from the housing the two rear most bearings and the direct drive gear will have been removed from the shaft 2 Press the remaining direct drive gear support bearing off of the shaft as shown See Fig 26 PRESS LI 26 3 Invert the shaft and remove the under drive gear and front support bearing as shown See Fig 27 PRESS Fig 27 4 This completes the disassembly of the input shaft 17 INTERMEDIATE SHAFT 1 After the
25. ring 4 in the order shown in figure 46 3 4 Install the front declutch gear locknut using 2 special socket 866 0687 004 and Loctite 290 on threads Torque to spec 2 5 This completes the rear output shaft assembly 8 gt 1 FRONT OUTPUT SHAFT ASSEMBLY Press bearing cups into the front output carrier using the special tool See Fig 44 NU d Fig 46 4 Install the end float set up tool or front output yoke and lock nut 22 5 Torque to spec using a fixture similar to that shown below See Fig 47 Fixture Fig 47 6 Using a dial indicator measure the shaft end float The clearance should be 003 to 008 inches loose see page 8 If the end float is not within specification a bearing spacer ring of a different thickness will need to be used See Fig 48 7 Place indicator base on this surface Fig 48 7 Remove the lock nut and end float set up tool 8 Install a new front output seal 9 This completes the front output assembly 23 Special Tool GENERAL ASSEMBLY 866 0780 1 2 If the bearing cups were removed from the rear carrier re install the shim stack into the intermediate shaft rear bearing bore See Fig 49 Fig 51 Fig 49 5 Place the housing into a suitable assembly stand on a sturdy workbench Install the bearing cups into the rear housing See Fig 52 using special tool 424 0443 S
26. te the transfer case Connect the transfer case mountings Since mounting designs vary consult vehicle service manual Connect the drivelines Connect the speedometer cable Connect the shift cylinder air lines Connect the indicator light and temperature sensor wires Fill the housing with the appropriate lubricant to the correct level and install the level plug Check the transfer case for leaks around the gaskets and seals DISASSEMBLY Disassembly and assembly of the Fabco TC 237 transfer case is a relatively simple procedure that can be made easier by the use of some very simple tooling Details of all tooling are given in the tooling section for manufacture in your own facilities or Fabco Automotive may be contacted for price and availability of all special tools listed throughout this manual GENERAL DISASSEMBLY 1 The transfer case should be drained cleaned and dried and removed from vehicle 2 The case may be disassembled on a clean workbench or floor as long as it is supported securely 3 Remove the side access cover from the case See Fig 1 Fig 3 5 Remove the high low shift cylinder cap bolts Then remove the cylinder cap and cylinder sleeve by sliding them off the piston See Fig 4 Fig 1 4 Remove and discard safety wire from the high low shift shaft bolts and then remove bolts using a double square socket See Figs 2 and 3 11 6 While holding the shift shaft piston
27. wo speed three shaft constant mesh design featuring a declutch for the front axle and underdrive engagement NOMINAL RATING Input Torque Input Horsepower Input Speed RATIOS High Low GEAR TYPE SHAFT SIZES Input amp Rear Output Front Output SHAFT SPACING Drop SHIFT MECHANISM BEARINGS LUBRICATION LUBRICANT OIL CAPACITY DRY WEIGHT HOUSING OPTIONS 6 000 Lb Ft 300 HP 3 200 RPM 1 1 2 22 1 Helical High Range and Spur Low Range 1 95 Inches 38 Involute Spline 2 25 Inches 10 Parallel Spline 12 00 Inches to Rear Output 12 00 Inches to Front Output Integral Air Cylinders Tapered Roller Splash See Page 6 6 5 Quarts U S 360 Lbs Aluminum Full Power PTO Mechanical Range Shift INPUT 2 5 FRONT DRIVE ENGAGEMENT INDICATOR SWITCH O 7 1 4 NPT FOR FRONT DRIVE ENGAGEMENT AIR OUTPUT TO LINE SPRING C RETURN FOR DISENGAGEMENT FRONT VIEW FABCO TC 237 TRANSFER CASE 1 4 NPT FOR UNDERDRIVE ENGAGEMENT AIR LINE SPRING RETURN FOR DIRECT DRIVE OUTPUT TO REAR DRAIN PLUG REAR VIEW FABCO TC 237 TRANSFER CASE LUBRICATION e RECOMMENDED LUBRICANTS On Highway Vehicles 1 Heavy Duty Engine Oil Temperature Grade Above 10 F SAE 50 Below 10 F SAE 30 Be sure to specify heavy duty type meeting MIL L 2
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