TC-200 Transfer Case Parts and Service Manual
Contents
1. We INTERMEDIATE SHAFT FRONT 2 OUTPUT 22 SHAFT 2 Ww OPTIONAL LUBRICATION PUMP FRONT DRIVE SHIFTER SHAFT Figure 1 2a TC 200 Sectional Views HIGH LOW RANGE SHIFTER SHAFT Rn INPUT SHAFT INTERMEDIATE SHAFT SHIFT FORK SHIFT FORK REAR DRIVE SHIFTER SHAFT REAR OUTPUT SHAFT Figure 1 2b TC 200 Sectional Views 2 LUBRICATION 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 duty2. 5 174 NOT DRAWN TO SCALE 4140 STEEL HARDEN WELDMENT TO Re 40 45 516 4 PLACES 90 Figure 8 1 866 0687 004 Bearing Locknut Wrench USED FOR SETTING THE SHAFT END FLOAT 3 2 998 2 327 A Yz K 2 69 1 75 06 003 8 2 317 2 3 75 2 yop 42 LEN 06 x 45 CHAMFER TYPICAL OF 4 MATERIAL MILD STEEL 3 75 2 565 9325 2 2 575 06 45 CHAMFER 7 TYPICAL OF 4 MATERIAL MILD STEEL Figure 8 2 884 246 Rear Output Shaft Sleeve Figure 8 3 Input Intermediate and Front Output Shaft Sleeve USED FOR SETTING THE GEAR END FLOAT 13 5 23 06 45 CHAMFER TYPICAL 4 MATERIAL MILD STEEL Figure 8 4 Rear Output Shaft Sleeve
3. Figure 4 16 Invert the shaft assembly in the press so that the remaining gear is supported See Figure 4 17 Remove the bearing cone assembly and the gear Remove the woodruff key if necessary AS Figure 4 17 FRONT OUTPUT SHAFT DISASSEMBLY Refer to Section P 4 in the parts manual 1 To facilitate reassembly the gear end float on the shaft should be checked prior to disassembly Install a dial indicator with a magnetic base as pictured in Figure 4 18 Lift upward on the gear and note the amount of end float The specified amount of end float is between 000 and 002 inches A greater amount usually indicates worn bearings Figure 4 18 Remove the bearing locknut with Fabco Tool 866 0687 004 or equivalent See Section 8 1 in this manual Lift off the spacer ring Place the shaft assembly in a press so that the clutch collar is supported and the press arbor bears against the end of the shaft Do not support the assembly by the gear See Figure 4 19 Remove the 3 bear ing cone assemblies the gear assembly the 2 spacer rings and the clutch collar Figure 4 19 4 Invert the shaft assembly the press so that the remaining bearing cone is supported See Figure 4 20 Remove the bearing cone assembly PRESS Figure 4 20 REAR OUTPUT SHAFT DISASSEMBLY Refer to Section P 5 in the parts ma
4. Figure 6 49 33 Install the breather vent and elbow in the front housing The vent must point toward the top of the transfer case See Figure 6 50 Figure 6 51 39 Install the intermediate shaft cap the front output shaft cap and the input shaft cap or power take off unit using the respective shim pack determined in Step 37 When installing the input shaft cap use the lifting bracket in place of the washer at the upper most location See Figure 6 52 Torque the 18 screws to specification Figure 6 50 34 Rotate the transfer case over so that its rear end is facing upward 35 Remove the rear output yoke or flange or Tool 844 0246 Figure 6 52 36 Remove the rear output carrier the front output shaft 40 If the unit is not equipped with a lubrication pump cap the intermediate shaft cap and the input shaft install the blanking cap with a new gasket on the cap or power take off unit intermediate shaft cap Torque the 6 cap screws to specification See Figure 6 53 37 To determine each correct shim pack thickness subtract the measured amount of end play from the If the unit is equipped with a lubrication pump follow shim pack thickness used 120 inch The result of the lubrication pump installation instructions the subtraction is the shim pack thickness that would contained in the PTO conversion kit provide for zero end float of the shaft Select a com bination of shims to add up to as close
5. AUTOMOTIVE CORPORATION TC 200 TRANSFER CASE SERVICE MANUAL Part Number 873 0042 001 FABCO AUTOMOTIVE CORPORATION Livermore CA www fabcoautomotive com Ph 925 454 9500 800 967 8838 FAX 925 454 9501 5 99 TABLE OF CONTENTS TC 200 TRANSFER CASE Introduction en LUBRICATION Recommended Lubricants Change Draining the Oil Refilling the Operating Temperature GENERAL INSTRUCTIONS DISASSEMBLY Preliminary Housing Disassembly Input Shaft Disassembly Intermediate Shaft Disassembly Front Output Shaft Disassembly Rear Output Shaft Disassembly CLEANING AND INSPECTION Drying and Corrosion Inhibition ASSEMBLY Assembly Precautions Input Shaft Assembly Intermediate Shaft Assembly Front Output Shaft Assembly Rear Output Shaft Assembly Housing Assembly TORQUE SPECIFICATIONS Recommended Torques SPECIAL TOOLS Bearing Locknut Wrench 866 0687 004 Rear Output Shaft Sleeve 884 0246 I
6. To avoid damage alkaline solutions should not be used DRYING AND CORROSION INHIBITION Dry 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 which are to be stored should also be wrapped in heavy waxed paper or plastic bags and kept dust free INSPECTION Prior to reassembly parts which 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 overheat ing Gears may also show pits as well as scoring and broken teeth Shafts may be nicked or marred or have damaged threads Parts which show any sign of damage should be repaired or replaced Inspect the rotor housing and idler of the oil pump if equipped for scoring Inspect the drive tab of the rotor assembly If any damage is noted the pump cartridge assembly should be replaced as a unit Check all shift forks and slots in sliding clutches for wear or discoloration due to heat Check the engaging teeth for a partial engagement wear pattern 6 ASSEMBLY ASSEMBLY PRECAUTIONS 1 Read the instructions completely before starting re assembly Refer to the appropriate exploded
7. bearing cone See Figure 6 18 19 Figure 6 18 8 A fabricated steel sleeve is desirable at this time to check the gear end float See Section 8 in this man ual for construction details If the construction of this sleeve is impractical skip to Step 12 but be sure to check the end float as directed in Step 10 9 Slip the fabricated sleeve over the shaft Install the bearing locknut with Fabco Tool 866 0687 004 or equivalent Torque to specification 10 Install a dial indicator as depicted in Figure 6 19 Lift upward on the gear assembly and note the gear end float on the dial indicator If the end float is not within specification 000 to 002 inch it will be necessary to disassemble the shaft by performing Steps 2 and 3 under FRONT OUTPUT SHAFT DISASSEMBLY in Section 4 Measure the thickness of the original spacer ring and select a new ring to provide end float within specification See item 10 in Section 5 in the parts manual for a list of available spacer rings Be sure to recheck the gear end float after a new spacer ring is installed Figure 6 19 11 After the correct end float is obtained remove the locknut and the fabricated sleeve 12 Be sure that the spacer ring is still in place Heat and install the shaft bearing cone assembly against the spacer ring Slide the remaining spacer ring against the bearing cone 13 14 Install the bearing locknut with Fabco Tool 866 0687 004 or equivale
8. against the bearing cone A fabricated steel sleeve is desirable at this time to check the gear end float See Section 8 in this manual for construction details If the construction of this sleeve is impractical skip to step 12 but be sure to check the end float as directed in step 10 16 9 Slip the fabricated sleeve over the shaft Install the 10 12 13 14 15 bearing locknut with Fabco Tool 866 0687 004 equivalent Torque to specification Install a dial indicator as depicted in Figure 6 4 Lift upward on the gear assembly and note the gear end float on the dial indicator If the end float is not within specification 000 to 002 inch it will be necessary to disassemble the shaft by performing Steps 2 and 3 under INPUT SHAFT DISASSEMBLY in Section 4 Measure the thickness of the original spacer ring and select a new ring to provide end float within specifica tion See item 12 in Section P 2 in the parts manual for a list of available spacer rings Figure 6 4 After the correct end float is obtained remove the locknut and the fabricated sleeve Be sure that the spacer ring is still in place Heat and install the shaft bearing cone assembly against the spacer ring Slide the remaining spacer ring against the bearing cone Install the bearing locknut with Fabco Tool 866 0687 004 or equivalent Torque to specification The gear end float should be rechecked at this time Invert th
9. and aprons should be worn whenever working around the suspected material NIOSH amp OSHA approved respirator masks suitable for asbestos dust should be worn at all times Disposable dust face masks are not allowed by OSHA 2 Do not smoke while working on any asbestos related material or wearing protective apparel 3 Do not eat or drink food while wearing protective clothing Always wash before eating or drinking 4 Do not use compressed air for any dirt removal Use only approved high efficiency vacuum cleaners suitable for use with asbestos Do not dry brush deposits or accumula tions of dirt from components What cannot be removed with the high efficiency vacuum cleaner should be washed with a water soaked rag The rag should not be wrung dry but should be disposed of together with other wastes containing asbestos in specially sealed and marked containers in accordance with EPA and OSHA regulations 5 Do not wear protective clothing away from the working area vacuum clean clothing before removal Shower if possible before going home These suggestions are neither complete nor authoritative on the subject of working with asbestos but are meant as a warning of possible risk It is the responsibility of the supervising authority to be aware of the possible dangers involved and to provide suitable training precaution and protection for those working in an asbes tos environment 4 DISASSEMBLY The disassembly and assembly procedu
10. as possible to this amount 26 41 42 43 44 Figure 6 53 Assemble the high low range air shift cylinder as follows Install two new O rings on the shift cylinder adapter tube and push into the rear transfer case housing bore See Figure 6 54 The end of the tube with the counterbore must face outward Figure 6 54 Install a new piston to shaft O ring over the threaded portion of the shaft Slide the spring over the shaft Note that this spring is longer than the rear output shift spring Place the nylon stop ring over the shaft and spring Install a new piston O ring in the deeper groove in the piston Position the piston on the shifter shaft The end of the piston with the O ring must face outward Push the piston down to compress the spring and install the shifter shaft washer and locknut See Figure 6 55 Torque the nut to specifi cation Soak the felt strip in gear oil and install in its groove on the piston Slip the air shift cylinder into position over the piston See Figure 6 56 Note that this cylinder is longer than the rear output shift cylinder Figure 6 56 45 Install a new O ring on the shift cylinder cap and insert into the cylinder Secure the assembly with the 4 cap screws and torque to specification See Figure 6 57 Figure 6 57 46 Assemble the rear output air shift cylinder similarly 47 If so equipped install the lubrication lines and a new filter 27 NOT
11. front output shaft up and tap down several times to seat the bearing cups Mount a dial indica tor as shown in Figure 6 42 Pry the shaft up and down and note the amount of end float 24 Figure 6 42 23 Pry the input shaft up and tap down several times to seat the bearing cups Mount a dial indicator as shown in Figure 6 43 Pry the shaft up and down and note the amount end float Figure 6 43 24 25 26 27 28 29 Working through the breather elbow hole in the front housing and the opening in the rear intermediate shaft cap tap the intermediate shaft up and down several times to seat the bearing cups Make sure that the shaft is all the way down before proceeding Install a dial indicator such that its probe is resting against the front of the intermediate shaft through the breather elbow hole See Figure 6 44 Figure 6 44 Push upward on the intermediate shaft and note the amount of end float on the dial indicator Repeat steps 24 through 26 several times to be sure of consistent results Assemble the front output shift cylinder as follows Install a new piston to shaft O ring over the threaded portion of the shifter shaft Slip the spring over the shaft Insert the nylon stop ring into the cylinder bore See Figure 6 45 Install the piston O ring in the deeper groove in the front output piston Soak the felt strip in gear oil and install in the other groove Insert the piston into i
12. hours off highway thereafter oil changes should be done at the following intervals On Highway Service 10 000 15 000 Miles Off Highway Service Logging dirt moving mining and associated 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 on the unit s 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 If the unit is equipped with an oil pump the lube oil filter should be replaced whenever the oil is changed The element is of the spin on type A film of clean oil should be applied to the rubber gasket of the new element before installing Do not overtighten 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 trans
13. type meeting MIL L 2104B 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 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 0 F use SAE 20W heavy duty engine oil meeting MIL L 2104B specifications NOTE Extreme pressure EP oils are no longer recom mended for use in Fabco transfer cases Under certain operating conditions these oils might form carbon depos its on gears shafts or bearings possibly causing mal functions and premature failure 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 40 Hours With every oil change the shift cylinder air lines and valves should be inspected for leaks and possible mal functioning 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
14. view in the parts manual All parts must be clean The gasket surfaces must be free of old gasket material Do not reuse old gas kets Bearing cup bores and shaft spline and bearing mounting surfaces should be coated with Lubriplate or equivalent This is necessary to reduce the possi bility of galling 15 All used seals must be replaced and the new seals should be coated with Loctite 601 or equiva lent on their outer diameter prior to being installed in their bores Their sealing lips should be coated with Lubriplate or equivalent to provide initial lubrication Any external cap screw not to be installed in a blind hole should have its threads coated with Permatex Form A Gasket 2 or equivalent non hardening sealer to prevent an oil leak All threaded fasteners should be tightened to the torque specified in the torque chart Any sharp edges on the seal diameter of the univer sal joint yoke or companion flanges should be removed with emery cloth The seal operating area should be coated with Lubriplate or equivalent bef ore installation Inmany 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 prop erties of the part Heated components should be al lowed to cool to room temperature before end float meas
15. ES 28 INPUT SHAFT 500 iy RR 2 Ja N ap INTERMEDIATE 72 5 SHAFT a Rig OPTIONAL 7 LUBRICATION PUMP 600 FRONT DRIVE SHIFTER SHAFT ALL SPECIFIED TORQUE VALUES ARE IN LB FT AND ARE FOR DRY NON LUBRICATED THREADS RECOMMENDED TORQUES ARE WITHIN 10 OF THE VALUES SHOWN HIGH LOW RANGE SHIFTER SHAFT INPUT SHAFT 30 INTERMEDIATE SHAFT SHIFT FORK REAR DRIVE SHIFTER SHAFT 30 REAR OUTPUT SHAFT Figure 7 1 TC 200 Recommended Torques 75 SQ BROACH THRU STAMP B66 687 004 5 75 05 X 45 229 5 1 25 USE 13 16 DRILL 25 16 23 25 15 X 45
16. NS The Fabco Model TC 200 Trans fer Case is a two speed four shaft constant mesh de sign with front and rear axle en gagement declutches 6 01 RATINGS Maximum Input Torque 7 000 Lbs Ft Maximum Input Horse power 300 HP Maximum Input Speed 2 800 RPM RATIOS Direct 1 1 Underdrive 2 11 1 GEAR TYPE Helical Case Hard ened SHAFT SIZES Early Production Units Input FrontOutput 2 250 Inches 10 Spline Rear Output 2 500 Inches 10 Spline SHAFT SIZES CurrentProduction Units Input FrontOutput 2 062 2 057 Inches 32 Involute Spline Rear Output 2 312 2 307 Inches 36 Involute Spline SHAFT SPAC ING DROP Rear Output 9 25 Inches Front Output 10 6 Inches 8 9 Inch Off set to Right SHIFT MECHANISM IntegralAirCylinders BEARINGS Tapered Roller OIL CAPACITY 5 5 Quarts WEIGHT 570 Lbs HOUSING Gray OPTIONS LubricationPump Full Power PTO HIGH LOW RANGE SHIFT CYLINDER _ FRONT DRIVE SHIFT CYLINDER REAR DRIVE SHIFT CYLINDER INPUT A 222 ge id CD CO a ek 4 i oo ee REAR OUTPUT OIL LEVEL PLUG PORT FOR OIL FRONT OUTPUT FRONT VIEW TEMP SENDER LEFT SIDE VIEW DRAIN PLUG REAR VIEW Figure 1 1 Fabco TC 200 Transfer Case INPUT SHAFT H 121
17. arts manual 4 Invert the shaft assembly in the press so that the 1 To facilitate reassembly the gear end float on the remaining gear is supported See Figure 4 14 shaft should be checked prior to disassembly Install Remove the bearing cone assembly and the gear a dial indicator with a magnetic base as pictured in Remove the woodruff key if necessary Figure 4 12 Lift upward on the gear and note the amount of end float The specified amount of end float is between 000 and 002 inches A greater amount usually indicates worn bearings Figure 4 14 12 INTERMEDIATE SHAFT DISASSEMBLY Refer to Section P 3 in the parts manual 1 To facilitate reassembly the gear end float on the shaft should be checked prior to disassembly Install a dial indicator with a magnetic base as pictured in Figure 4 15 Lift upward on the gear and note the amount of end float The specified amount of end float is between 000 and 002 inches A greater amount usually indicates worn bearings Figure 4 15 Remove the bearing locknut with Fabco Tool 866 0687 004 or equivalent See Section 8 1 in this manual Lift off the spacer ring Place the shaft assembly in a press so that the clutch collar is supported and the press arbor bears against the shaft Do not support the assembly by either one of the gears See Figure 4 16 Remove the 3 bearing cone assemblies the gear assembly the spacer ring and the clutch collar
18. ask 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 move ment Do not rely the vehicle being in gear with a dead engine to prevent movement All work should be performed on a flat level surface free of loose ma terial When having to work under a vehicle it should be raised and supported with appropriate frame stands or very secure blocking 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 specifications of the applicable service manual Caution must be exercised when cleaning the com ponent 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 should be used in accordance with their labelling instruc tions 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 Fabco has not used A
19. ce In the steps that follow a selected shim pack is used to adjust the end float of each of the assemblies The correct setting is 003 to 008 inches See the parts manual for a list of available shims Temporary guide studs may be used to assist in locating the shims and the cap or carrier To make the studs cut the heads off of two 7 16 14 x 2 inch long cap screws 16 Temporarily install the rear output carrier with shim pack thickness of 120 inch See Figure 6 39 17 18 19 Figure 6 39 For convenience Fabco Tool 884 0246 may be used during the shim selection procedure See Section 8 2 in this manual Temporarily install the rear output yoke or flange or Tool 884 0246 Torque the locknut to specification Pry the rear output shaft up and tap down several times to seat the bearing cups Mounta dial indicator as shown in Figure 6 40 Pry the shaft up and down and note the amount of end float Figure 6 40 Temporarily install the intermediate shaft cap the input shaft cap and the front output shaft cap with a shim pack thickness each of 120 inch See Figure 6 41 Install the power take off unit in place of the input shaft cap if the unit is so equipped See the parts manual for a list of available shims Figure 6 41 20 Rotate the unit over so that its front face is upward 21 Install the input and front output yokes or flanges Torque their locknuts to specification 22 Pry the
20. d remove the lubrication lines and oil off the cylinders and caps filter Note the location and routing of the lines so that they may be correctly reinstalled 6 Remove the nut from each piston Exercise caution as the pistons are spring loaded Remove the HOUSING DISASSEMBLY washer piston spring and nylon stop ring from each assembly 1 Remove the front drive indicator switch washer and 1 a pin See Figure 4 2 7 If the unit is equipped with a lubrication pump re move the 4 cap screws securing the pump assem bly Lift off the pump assembly and gasket Discard the gasket Remove the pump assembly by lifting from the shaft 8 If the transfer case is equipped with a power take off remove the 6 larger 5 8 hex cap screws and washers securing the power take off unit to the transfer case housing Lift the power take off unit clear as an assembly 10 9 Remove the remaining caps and carriers from the 10 11 rear housing half Keep the shims together with its cap or carrier to facilitate reassembly Be sure the rear face of the transfer case is up ward and that the unit is attached to the holding fixture by its front case half only Remove the 23 12 point cap screws and washers See Figure 4 4 Figure 4 4 Separate the housing halves If difficulty is encoun tered temporarily install 3 8 16 bolts into the two tapped holes in the front housing half to force the housing halves apart See Fig
21. de be jacked up in order to achieve sufficient clearance to replace the transfer case between the frame rails Raise the transmission jack to properly locate transfer case Connect transfer case mountings Since mounting designs vary consult vehicle service manual Connect drivelines Connect speedometer wiring Connect shift cylinder air lines Connect indicator light and temperature sensor wires Fill housing with appropriate lubricant to correct level and install fill plug Check transfer case for leaks around gaskets and seals ASBESTOS WARNING SUGGESTED PROCEDURES FOR WORKING WITH COMPONENTS SUSPECTED OF CONTAINING ASBESTOS Asbestos has been found to be a primary cause of various forms of respiratory disease and cancer of several vital body organs Primary ingestion is by breathing or swallowing dust containing fibers and can place smokers at a greater risk than those who do not smoke The onset of disease can be at an extended period of time Several years after the expo sure The Occupational and Safety Health Administration OSHA has established very stringent limitations for exposure to asbestos fibers by workers using the material and every precaution should be taken to minimize the risks involved The following are some suggested procedures to adopt when working with material that has or may be suspected of containing asbestos 1 Approved protective clothing gloves eye shield
22. e assembly and install the sliding clutch collar The external teeth on the collar must face downward See Figure 6 5 Figure 6 5 3 Heat and install the smaller of the two gears 16 Heat and install the remaining gear See Figure 6 6 See Figure 6 9 Figure 6 6 Figure 6 9 17 Heat and install the front bearing cone assembly against the gear See Figure 6 7 4 Heat and install the rear bearing cone assembly against the gear See Figure 6 10 Fi 6 7 Figure 6 10 INTERMEDIATE SHAFT ASSEMBLY 5 Invert the assembly install the sliding clutch collar The external teeth on the collar must face Refer to Section P 3 in the parts manual upward See Figure 6 11 1 Install the woodruff key Be sure of the correct key The intermediate shaft key is 2 5 16 inches long while the input shaft key is 2 inches long 2 Position the shaft as shown in Figure 6 8 Figure 6 11 6 Heat and installa gear bearing cone assembly one of the narrower two against the shaft shoulder Figure 6 8 17 7 Slide the bearing spacer ring against the cone See 10 11 Figure 6 12 Note that the bearing spacer ring is a select fit part that is used to adjust the gear end float If the end float checked prior to disassembly was within specification 000 to 002 inch and no parts were replaced the original bearing spacer ring should provide the correct end float upon reassem bly Figure 6 12 Press th
23. e two bearing cups into the gear Be sure that the cups are seated Position the gear assembly onto the shaft The face of the gear with the internal clutch splines must face downward Heat and install the remaining gear bearing cone assembly against the bearing spacer ring See Figure 6 13 Figure 6 13 A fabricated steel sleeve is desirable at this time to check the gear end float See Section 8 in this manual for construction details If the construction of this sleeve is impractical skip to step 14 but be sure to check the end float as directed in Step 12 Slip the fabricated sleeve over the shaft Install the bearing locknut with Fabco Tool 866 0687 004 or equivalent Torque to specification 12 Install a dial indicator as depicted in Figure 6 14 Lift upward on the gear assembly and note the gear end float on the dial indicator If the end float is not within specification 000 to 002 inch it will be necessary to disassemble the shaft by performing Steps 2 and 3 under INTERMEDIATE SHAFT DISASSEMBLY Section 4 Measure the thickness of the original spacer ring and select a new ring to provide end float within the specification See item 8 in Section P 3 or P 4 in the parts manual for a list of available spacer rings Figure 6 14 13 After the correct end float is obtained remove the locknut and the fabricated sleeve 14 Heat and install the shaft bearing cone assembly against the gear bearing co
24. fer case with the appropriate oil with the vehicle on level ground Fill the transfer case to the level of the fill plug For each transfer case the oil capacity will vary some what depending on the model and the inclination of the unit therefore always fill to the level of the fill plug Do not overfill Inspect for leaks OPERATING TEMPERATURE The operating temperature of the transfer case should not exceed 250 F 120 C Extensive operation at temperature exceeding 250 F will result in rapid break down of the oil and may shorten the transfer case life If reduction of operating speed is not acceptable then the case may have to be equipped with an external oil cooler to maintain the operating temperature below 250 F The following conditions may contribute to excessive oil temperature 1 3 A vehicle remaining stationary for extended periods while operating the power take off A vehicle which is used in tropical or desert condi tions Avehicle where extended body work or an accumu lation of dirt and plant material may shield the case from air ventilation and circulation Avehicle that is operated for extended distances at high speed with the main transmission in overdrive GENERAL INSTRUCTIONS SAFETY The servicing and maintenance of components from any automotive vehicle present possible hazards and every endeavor should be made to minimize the risks taken to successfully complete the t
25. he two shift shaft bores in the front housing half Use a non hardening sealer to prevent an oil leak See Figure 6 26 21 Figure 6 26 2 Install the input and the front output shaft oil seals in the front housing half See Figure 6 26 3 Mount the front housing half to the work fixture as shown in figure 6 27 Figure 6 27 4 Tap the two hollow dowel pins into place in the front housing half See Figure 6 28 Figure 6 28 5 Install the 4 bearing cups into the inside of the front 8 Assemble the rear output shift fork to the shift shaft housing half See Figure 6 29 observing the orientation depicted in Figure 6 32 Install the fork locking screw Be sure that the screw is seated in the shaft groove Torque to specification and lockwire to the shaft as shown in Figure 6 32 Figure 6 29 6 Lower the intermediate shaft subassembly into place larger gear down See Figure 6 30 Figure 6 32 9 Position the rear output shift shaft fork subassembly to the rear output shaft clutch collar and lower into place See Figure 6 33 Figure 6 30 7 Position the front output shift shaft fork to the front output shaft clutch collar and lower into place gear end upward See Figure 6 31 Figure 6 33 10 Lower the input shaft subassembly into place smaller gear downward See Figure 6 34 Figure 6 31 Figure 6 34 22 11 Position a shift fork to the input shaft clutch collar the
26. ne Slide the remaining spacer ring against the bearing cone 15 Install the bearing locknut with Fabco Tool 866 0687 004 or equivalent Torque to specification 16 The gear end float should be rechecked at this time FRONT OUTPUT SHAFT ASSEMBLY Refer to Section P 4 in the parts manual 1 Heat and install the front bearing cone assembly against the shaft shoulder After the bearing cools to room temperature position the shaft as shown in Figure 6 15 Figure 6 15 18 2 With its external teeth facing upward slip the clutch collar over the shaft as shown in Figure 6 16 Figure 6 16 3 Heat and install a gear bearing cone assembly one of the narrower two against the shaft shoulder See Figure 6 17 Figure 6 17 Slide the bearing spacer ring against the cone Note that the bearing spacer ring is a select fit part that is used to adjust the gear end float If the end float checked prior to disassembly was within specifica tion 000 to 002 inch and no parts were replaced the original bearing spacer ring should provide the correct end float upon reassembly Press the two bearing cups into the gear Be sure that the cups are seated Position the gear assembly onto the shaft The face of the gear with the internal clutch splines must face downward Heat and install the remaining gear bearing cone assembly against the bearing spacer ring Slide the larger of the remaining spacer rings against the
27. nput Intermediate and Front Output Shaft Sleeve Rear Output Shaft Sleeve ILLUSTRATED PARTS 22022 iii Copyright Fabco Automotive Corporation 151 Lawrence Drive Livermore CA 94551 NNNNNN 00 29 1 200 TRANSFER CASE INTRODUCTION The Fabco Model TC 200 is a two speed four shaft trans fer case for use in all wheel drive vehicles The front out put shaft is off set to the right to com ple ment a spe cial off set front axle as sem bly All shiffing is com plished by in te gral air actuated cylinders Early pro duction ver sions of the TC 200 were equipped with parallel sided spline in put and out put shafts while later pro duction mod els utilize in vo lute spline shafts All TC 200 trans fer cases have pro visions for an electro magnetic speed ome tersensor The addition ofa lu bri ca tion pump and ade clutch able power take off unit may be ac com plished by parts kits avail able from Fabco The front drive axle may be en gaged at any ve hi cle speed pro vided the rear wheels are not spinning Shifts be tween ranges how ever mustbe made while the ve hi cle is station ary to avoid serious dam age to the trans fer case The 20015 also equipped with a rear drive de clutch which is nor mally kept en gaged un less the op tional PTO unit is in operation SPECIFICATIO
28. nt Torque to specification The gear end float should be rechecked at this time REAR OUTPUT SHAFT ASSEMBLY Refer to Section P 5 in the parts manual 1 Heat and install the front bearing cone assembly against the shaft shoulder After the bearing cools to room temperature position the shaft with the bear ing downward With its external teeth facing upward slip the clutch collar over the shaft as shown in Figure 6 20 Figure 6 20 Heat and install a gear bearing cone assembly one of the narrower two against the shaft shoulder Slide the bearing spacer ring against the cone See Figure 6 21 Note that the bearing spacer ring is a select fit part that is used to adjust the gear end float If the end float checked prior to disassembly was within specification 000 to 002 inch and no parts were replaced the original bearing spacer ring should provide the correct end float upon reassem bly Figure 6 21 20 5 Press the two bearing cups into the gear Be sure that the cups are seated Position the gear assembly onto the shaft The face of the gear with the internal clutch spline must face downward See Figure 6 22 Figure 6 22 Heat and install the remaining gear bearing cone assembly against the bearing spacer ring Slide the thin spacer ring against the bearing cone See Figure 6 23 Figure 6 23 A fabricated steel sleeve is desirable at this time to check the gea
29. nual 1 To facilitate reassembly the gear end float on the shaft should be checked prior to disassembly Tem porarily install the drive yoke or flange on the shaft and torque the locknut to specification For conven ience Fabco Tool 884 0246 may be used instead of the yoke See Section 8 2 in this manual Install a dial indicator with a magnetic base as pictured in Fig ure 4 21 Lift upward on the gear and note the amount of end float The specified amount of end float is between 000 and 002 inches A greater amount usually indicates worn bearings Remove the drive yoke Place the shaft assembly in a press so that the clutch collar is supported and the press arbor bears against the end of the shaft Do not support the assembly by the gear See Figure 4 22 Remove the speed ometer sensor gear and its spacer the 3 bearing cone assemblies the gear assembly the two spacer rings and the clutch collar Figure 4 22 4 Invert the shaft assembly in the press so that the remaining bearing cone is supported See Figure 4 23 Remove the bearing cone assembly Figure 4 23 5 CLEANING AND INSPECTION 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 Parts should be cleaned with emulsion cleaners or petro leum solvents
30. r end float See Section 8 in this man ual for construction details If the construction of this sleeve is impractical perform Step 12 and then tem porarily install the yoke or flange or Fabco Tool 884 0246 and check the end float as directed in Step 10 Slip the fabricated sleeve over the shaft Install the yoke retaining nut and torque to specifications 10 11 12 Install a dial indicator as depicted Figure 6 24 Lift upward on the gear assembly and note the gear end float on the dial indicator If the end float is not within specification 000 to 002 inch it will be necessary to disassemble the shaft by performing Steps 2 and 3 under REAR OUTPUT SHAFT DISASSEMBLY in Section 4 Measure the thickness of the original spacer ring and select a new ring to provide end float within specification See item 7 in Section P 6 in the parts manual for a list of available spacer rings Be sure to recheck the gear end float after a new spacer ring is installed Figure 6 24 After the correct end float is obtained remove the locknut and the fabricated sleeve Be sure that the spacer ring is still in place Heat and install the shaft bearing cone assembly against the spacer ring Slide the spacer sleeve and then the speedometer sensor gear against the bearing cone The sensor gear may be heated if necessary See Figure 6 25 Figure 6 25 HOUSING ASSEMBLY 1 If removed install new expansion plugs into t
31. remaining shift fork to the intermediate shaft clutch collar observing the directions as in Figure 6 35 Locate the shift fork bores in line with the shaft bore in the front housing half 12 13 Figure 6 35 Insert the high low range shift shaft through the bores in the shift forks and into the bore in the front housing threaded end of the shaft upward See Figure 6 36 Figure 6 36 Install the input shaft shift fork locking screw and torque to specification Be sure that the screw is seated in the lower groove Rotate both shift forks clockwise until no further movement is possible Install the intermediate shaft shift fork locking screw and torque to specification insuring that the screw is seated in its groove Attempt to rotate the shift shaft back and forth There should be some obvious free play Lockwire the two screws as shown in Figure 6 37 E93 14 15 Figure 6 37 Gently tap the four bearing cups into the rear case half bores See Figure 6 38 Figure 6 38 Place a new housing gasket over the two hollow dowel pins and lower the rear housing half into place Secure with two of the 4 inch long hex head bolts at the pin locations The remaining 4 inch long bolt is to be used with the lifting bracket at the loca tion pictured in Figure 1 1 Use two flat washers between the bracket and the housing Install the remaining 18 bolts Torque all 21 bolts to specifi cation in a criss cross sequen
32. res in this man ual are based on the four shaft subassemblies Input in termediate front output and rear output The shift components and power take off unit are considered separately The components for each subassembly should be kept together to avoid unnecessary confusion upon reassembly PRELIMINARY STEPS 1 After removing the transfer case from the vehicle thoroughly clean the exterior Figure 4 2 2 Remove the drain plug and drain the oil 2 Remove the 4 cap screws securing the front output shift cylinder cap transfer case front face Remove the cap and discard the O ring See Figure 4 3 3 Mount the transfer case in a suitable fixture The ideal fixture would be such that the transfer case can be rotated so that either the front or the rear of the case is facing upward The transfer case must be attached by its front housing half only A unit mounted in a typical fixture is shown in Figure 4 1 If the fixture does not allow rotation mount the unit with its rear end facing upward Figure 4 3 3 Remove the nut from the piston Exercise caution as the piston is spring loaded Remove the washer piston spring and nylon stop ring Figure 4 1 4 Position the transfer case with its rear face upward 4 Remove the input front output and rear output drive yokes or flanges 5 Remove the 4 cap screws securing the two remain ing shift cylinder caps transfer case rear face Lift 5 If so equippe
33. sbestos in any of its products manufactured since May of 1989 and was used only in axle brake linings prior to that time See the sepa rate Asbestos Warning if you suspect asbestos may be present on the vehicle or component in the area to be serviced REMOVAL FROM VEHICLE 1 a O 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 wiring Disconnect drivelines at flanges or yokes Position a transmission jack of suitable capacity beneath the transfer case The transfer case must be seated on the jack in a safe and firm position Disconnect transfer case mountings at rubber shock insulators Since mounting designs vary consult vehicle service manual After inspecting that all mountings and connections to the transfer case are 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 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 INSTALLATION INTO VEHICLE N Place transfer case on transmission jack Position transmission jack underneath vehicle Some vehicles may require that one si
34. ts bore The end of the piston with the felt strip must go in first See Figure 6 46 Install the washer and nut over the piston Torque the nut to specification 30 31 Figure 6 46 Install a new O ring on the shift cylinder cap Install the cap such that the air inlet port points away from the front output shaft See Figure 6 47 Torque the four cap screws to specification Figure 6 47 Insert the front drive indicator switch actuating pin into place The rounded end of the pin must face inward See Figure 6 48 Install the switch using a new copper washer and torque to specification Figure 6 48 32 At this point it is advantageous to verify the opera See the parts manual for a list of available shims tion of the shift indicator switch Apply and release Since the thinnest shim available is 002 inch thick shop air 150 psi maximum to the shift cylinder while the shim pack may be plus or minus 001 inch from observing switch operation with a continuity tester the desired amount If this procedure is carefully See Figure 6 49 It may be necessary to rotate the followed the shaft end float after reassembly should gear train slightly to permit clutch engagement be within the specified range of 003 to 008 inches Always recheck the final end float with the dial indicator 38 Press the oil seal into the rear output carrier Figure 6 51 and install on the transfer case using the shim pack determined in Step 37
35. ure 4 5 Lift the rear housing half clear Discard the housing gasket See Figure 4 6 Figure 4 6 12 Cut the lockwires and remove the 2 shift fork screws from the high low range shifter shaft Lift the shifter shaft out See Figure 4 7 Remove the 2 shift forks Figure 4 7 13 Lift the input shaft subassembly from the housing See Figure 4 8 Figure 4 8 14 Lift the rear output shaft subassembly together with its shifter shaft subassembly from the housing Do not force it may be necessary to rock the shifter shaft from side to side to prevent binding See Figure 4 9 Figure 4 9 11 15 Lift the front output shaft subassembly together with its shifter shaft fork from the housing See Figure 4 10 Figure 4 12 2 Remove the bearing locknut with Fabco Tool Figure 4 10 866 0687 004 or equivalent See Section 8 1 in this manual Lift off the spacer ring 16 Lift the intermediate shaft subassembly from the case See Figure 4 11 3 Place the shaft assembly in a press so that the clutch collar is supported and the press arbor bears against the end of the shaft Do not support the assembly by either one of the gears See Figure 4 13 Re move the 3 bearing cone assemblies the gear as sembly the two spacer rings and the clutch collar Figure 4 11 SUBASSEMBLIES INPUT SHAFT DISASSEMBLY Figure 4 13 Refer to Section P 2 in the p
36. urements are made CAUTION Although Fabco does not recommend its use in transfer cases if a formed in place gasket is used for repair extreme caution must be exercised to prevent the compound from entering bearings oil galleries pas sages or tapped holes All beads must be kept smaller than 125 inch diameter INPUT SHAFT ASSEMBLY Refer to Section P 2 in the parts manual 1 Install the woodruff key Be sure of the correct key The input shaft key is 2 inches long while the inter mediate shaft key is 2 5 16 inches long 2 Position the shaft as shown in Figure 6 1 3 Heat and install a gear bearing cone assembly of the narrower two against the shaft shoulder See Figure 6 2 Figure 6 2 4 Slide the bearing spacer ring against the cone Note that the bearing spacer ring is a select fit part that is used to adjust the gear end float If the end float checked prior to disassembly was within specifica tion 000 to 002 inch and no parts were replaced the original bearing spacer ring should provide the correct end float upon reassembly Press the two bearing cups into the gear Be sure that the cups are seated Position the gear assembly onto the shaft The face of the gear with the internal clutch splines must face downward See Figure 6 3 Figure 6 3 Heat and install the remaining gear bearing cone assembly against the bearing spacer ring Slide the larger of the remaining spacer rings
Download Pdf Manuals
Related Search