TC-65, TC-80, TC-110 & PTO-110 Service Manual
Contents
1. 9 Intermediate Shaft Disassembly 10 H Output Shaft Disassembly 10 1 Oil Pump Disassembly 11 V Cleaning and Inspection A Choice of Cleaning Methods 12 B Drying and Corrosion Inhibition 12 C Inspection es 12 VI Transfer Case Assembly A General Precautions for Reassembly 13 B Input Shaft Assembly 14 C Intermediate Shaft Assembly 15 D Output Shaft Assembly 16 E Main Housing Assembly 17 F Declutch and PTO Assembly 20 G Shift Cylinder Assembly and Adjustment 22 Oil Pump 23 1 Final lt 23 625 403A Copyright 1984 by Fabco Automotive Livermore California 94551 DIRECT PUMP DRIVE OPTIONAL FRONT VIEW 165 CONTROL FLANGE 1550 1710 SERIES SWITCH SHIFT INDICATOR SWITCH SHIFT INDICATOR H N CONTROL H N CONTROL 73 818 1 5 FLANGE 1710 SERIES OPTIONAL 4 180 SERIES 10 NC 6 HOLES EACH SIDE Ss GN 7 lt FRONT DRIVE CONTROL FLANGE 1710 SERIES OPTIONAL 1810 SERIES 736 teno SIDE VIEW LH SWITCH SHIFT INDICATOR TC 65 TC 80 TC 110 TRA2. Fig 4 3 Remove locknut and washer from rear of shaft and slide blanking sleeve from the shaft Discard locknut and replace with a new locknut at assembly The direct drive gear and remaining parts can now be disassembled NOTE The standard case has a splined sleeve on the rear of the input shaft called a blanking sleeve On cases with PTO or direct pump drive this sleeve is replaced by a gear identical to the front output shaft declutch gear to furnish a drive for the PTO Other than having external teeth to drive the PTO the declutch gear is identical to and has the same function as the blanking sleeve that of carrying the rear bearing cone Hereafter to simplify technology the part will be referred to as the blanking sleeve even if it is actually a declutch gear The front output part will be referred to as a declutch gear since a blanking sleeve is never used in this position If necessary remove the roller bearing cone from the blanking sleeve TC 80 1 Slide the spacing sleeve clutch gear and clutch collar from the shaft Remove locknut and washer from rear of shaft and slide blanking sleeve from the shaft Dis card locknut and replace with a new locknut at assembly The direct drive gear and remaining parts can now be disassembled If necessary remove the roller bearing cone from the blanking sleeve IV TRANSFER CASE DISASSEMBLY F Input Shaft Disassembly cont TC 110 1 S
3. 65 80 amp 110 TRANSFER CASE AND PTO 110 SPLIT SHAFT SERVICE MANUAL P N Telephone 925 454 9500 Fax 925 454 9501 151 Lawrence Livermore CA 94551 AUTOMOTIVE CORPORATION www fabcoautomotive com 3 s Fabco Automotive Corporation Service and Parts Manual Models TC 65 TC 80 TC 110 and PTO 110 TABLE OF CONTENTS Operating Instructions VII Torque Specifications 24 A FORE DIlVO 3 Vill Parts Manual 25 B Underdrive TC 65 Only C Power Take Off o9 9 9 9 9 9 Lubrication PARTS MANUAL Transfer Case Oil Change STARTS ON PAGE 25 Draining Oil Refilling Oil INSDEGION S s exse x PER SEX ERU Operating Temperature Shift Cylinder Inspection 9 9 9 9 9 9 Transfer Case Removal and Installation A Removal from Vehicle 6 B Installation into Vehicle 6 IV Transfer Case Disassembly A General Precautions for Disassembly 7 B Preparation for Disassembly 7 C Shift Cylinder Disassembly 7 PTO and Declutch Disassembly 8 Splitting the Main Housing 9 Input Shaft Disassembly
4. used Snap Rings Remove snap rings with pliers or special tools designed for this purpose Rings removed in this manner can be reused When necessary to apply a force to remove a part use of a puller or press would be preferred However sometimes it may be necessary to use a soft hammer or mallet The PTO 110 a variant configuration of the TC 110 is used for a Split Shaft Power Take Off Refer to the TC 110 instructions for assembly and disassembly Minor differences are noted in the TC 110 text gt The 110 is installed reversed so TC 110 front is the same as PTO 110 back and shaft rotations are reversed The PTO 110 oil pump is assembled to pump in reverse rotation so trans fer case and Power Take Off oil pumps are NOT interchangeable Preparation for Disassembly After removing the transfer case from the vehi cle remove any mounting brackets still attached to the transfer case Remove oil lines if so equipped Shift Cylinder Disassembly High Neutral Underdrive Remove four bolts from the shift cylinder cap and remove cap from shift cylinder Discard O ring from cylinder cap if replacement is neces sary Remove shift cylinder tube from the shift cylin der adapter tube located in the housing ex posing piston Disassemble shift piston from the shift shaft and discard O ring and felt wiper if replacement is necessary Remove shift shaft spring and plastic
5. Fig 9 TC 110 Input Shaft Assembly VI Input Shaft Assembly continued TC 110 see fig 9 1 If the inner thrust washer and needle bearing race have been removed from the rear of the input shaft place the thrust washer 148 thick over the shaft and against the raised teeth of the gear Oil groove side of washer to face outwards and toward where the direct drive gear will be placed Heat the inner race in an oven to about 200 250 drop over shaft and tap down to the inner thrust washer with a suitable driver the roller bearing inner race must be snug against the inner thrust washer Slide two roller bearing assemblies and spacer ring over the roller bearing inner race located at the rear of the shaft Grease the roller bearing assemblies and the inner diameter of the direct drive gear Slide the gear over the rear of the shaft Place the gear spacer 5 g thick over the rear of the shaft and against the gear Oil groove side of washer must face gear Press the roller bearing cone over the blanking sleeve Slide the blanking sleeve onto the splines located at the rear of the shaft Secure blanking sleeve to shaft with the washer and locknut Tighten locknut to correct torque Check thrust clearance as before 015 020 Slide clutch collar over the front of the shaft and over the raised teeth of the input shaft short hub to face direct drive gear see fig 5 Slide spacer ring 21 32 thi
6. Use care to avoid dis torting pump housing by excessive tightening of vise 2 Remove any burrs on shaft drive tang 3 Remove housing plug with a suitable spanner wrench 4 Remove from vise and punch match marks or paint dab on cover and body for reassembly 5 Remove capscrews cover idler and rotor from housing 6 Check pump housing rotor idler gear idler pin and crescent for wear chipped or broken teeth 7 Housing bore and rotor O D may be checked for wear by positioning rotor in the housing and check for clearance in the bearing The shaft must turn freely without any detectable side play Any side play will require replacement of housing rotor or both If both housing and rotor require replacing it is economically advisable to replace the pump NOTE The PTO 110 pump has the cover re versed to allow flow in the opposite rotation direction Note the position of the notch in the cover prior to disassembly CLEANING AND INSPECTION A Choice of Cleaning Methods 1 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 tightly closing breather caps and other openings 2 Rough parts such as the housing which are too large to conveniently clean with solvents may be immersed in a hot solution tank containing a mild alkaline solution Parts cleaned in hot solution tanks must be rinsed thoroughly to prevent
7. better determine their own oil change and inspection periods A Transfer Case Oil Change Transfer case lubricant should be changed on all new transfer cases after the first 3 000 to 5 000 miles on highway or first 40 hours off highway there after oil changes should be done at the following intervals On Off Highway Service 10 000 15 000 miles Off Highway Service Logging dirt moving mining and associated operations 500 750 hours as indicated by operation and contamination of lubricant B Draining Oil Draining is best accomplished after the vehicle has been operated briefly allowing the oil to become warm and flow freely Remove both drain and fill plugs and allow housing to empty completely After transfer case has been drained and before it is refilled the case should be thoroughly flushed with clean flushing oil or kerosene C Refilling Oil If the transfer case has been removed from the vehicle for service it is best to refill the oil after the transfer case has been reinstalled into the vehicle Clean and replace drain plug and fill the transfer case with appropriate gear oil with the vehicle on level ground see recommended lubricant chart Fill transfer case to the level of the fill plug metering approximately 10 quarts of gear oil into the transfer case The exact amount may differ depending upon the inclination of the transfer case Always fill to the level of the fill pl
8. damage by traces of alkaline material 3 Parts with ground or polished surfaces such as bearings gears and shafts should be cleaned with emulsion cleaners or petroleum solvents Alkaline hot solution tanks may damage the machined surfaces and such cleaning methods should be avoided B Drying and Corrosion Inhibition Soft clean shop towels should be used to dry parts after cleaning Compressed air may be used to clean inaccessible areas of large parts such as the hous ing Bearings should not be spun dry with compressed air as the lack of lubrication may cause damage to the mating surfaces 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 C 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 overheating Gears also may show pits as well as scoring and broken teeth Shafts may be nicked or marred or may have damaged threads Parts which show any signs of damage should be repaired or replaced Check all shift forks and slots in sliding clutches for extreme wear or discoloration from heat Check engaging teeth of sliding clutches for partial engageme
9. fig 34 TRANSFER CASE ASSEMBLY Fig 32 Fig 34 22 VI Coat the shift cylinder tube lightly with lubri cant install cylinder tube over piston and seat cylinder tube over O ring in the adapter tube Install O ring in shift cylinder cap and install cylinder cap into the cylinder tube Secure assembly with bolts and tighten bolts evenly to prevent misalignment of cylinder cap Tighten bolts to correct torque Unscrew adjusting bolt at input front side of case until approximately 172 inches protrude from housing Be sure that bolt end is not touch ing the end of the shaft at full stroke with air applied to the cylinder Apply air pressure to the cylinder Run the ad justing bolt in until the end of the bolt makes contact with the shift shaft in the case Turn the bolt inward 72 turn from this point and tighten the jam nut Oil Pump Assembly Install rotor in pump body Apply gasket s to cover Place idler gear on pin in cover assembly Place cover assembly with idler gear on pump housing Use care to align matching marks for proper location Insure the cover notch is in same position as when removed Install cover plate capscrews securely Pull down gradually and alternate from a screw on one side to one on the opposite side Install and tighten housing plug with appropri ate spanner wrench Check pump for free rotation by turning shaft shaft should turn freely by ha
10. Assemble PTO housing or rear cap to housing and secure with the proper bolts Tighten bolts to correct torque See Part F this section for PTO assembly 10 Tap intermediate shaft down to seat the shaft into the bearings and related parts Place inter mediate shaft rear cap into the rear housing bore Measure with feeler gauges the amount of clearance see fig 20 Add 005 to this dimen sion and add the necessary shims to match that calculated dimension Assemble rear cap to housing and secure with six bolts Be sure to align the oil passages Tighten bolts to correct torque Fig 20 18 VI the oil passages Assemble speedometer gear spacer and speedometer drive gear to the com panion flange Assemble the rear output com 10 12 13 14 15 16 17 TRANSFER CASE ASSEMBLY panion flange with a washer and locknut see fig 21 Tighten locknut to correct torque Assemble speedometer driven gear and adapter to carrier see fig 22 TC 80 amp 110 only Press seal into output shaft rear seal carrier Assemble seal carrier and gasket to housing with six bolts Be sure to align oil passages Tighten bolts to correct torque Slide rear output companion flange onto the splines TC 110 must be started into the rear bearing cone and driven in Secure flange with washer and locknut Tighten locknut to correct torque Turn housing assembly over to position front of case facing up S
11. NSFER CASE LEVEL OPTIONAL 18 gt BOH Oy A H g al lt 9 x 437 PIPE PLUG DRAIN 3 4 PIPE PLUG dt REAR VIEW SPEEDO DRIVE 76 65 ONLY OIL LINES NOT SHOWN TRUE POSITION FRONT PTO OUTPUT SIDE VIEW RH REAR VIEW FLANGE LINES NOT SHOWN FLANGE 1810 OR 1710 IN TRUE POSITION 1810 OR 1710 SERIES 7 SERIES DUAL PTO OUTPUT SIDE VIEW 88 i 5 5 FLANGE 1810 OR 170 N SERIES ae 3 4 10 NC_6 HOLES N m REAR INPUT AXLE i 7 FLANGE 1810 OR 1710 i SERIES ue U N DECLUTCH FLANGE CONTROL 1610 OR 1710 SERIES SIDE VIEW RH PTO 110 SPLIT SHAFT PTO DUAL PTO OUTPUT FRONT VIEW 18 ___ CONTROL OL LEVEL 3 PIPE PLUG 29 7m D PIPE PLUG FRONT VIEW t INPUT 12 00 BETWEEN SHAFTS FRONT OUTPUT M TC 65 weur il HS E e 4 i o z tb Q e FRONT OUTPUT Us TC 80 12 00 BETWEEN SHAFTS REAR i FRONT OUTPUT OUTPUT TC 110 DIRECT PUMP DRIVE WITH SHIPPING COVER PT
12. O ASSEMBLY TC OPTIONS REAR FRONT PTO OUTPUT ae gt OUTPUT LE OUTPUT PTO 110 OPERATING INSTRUCTIONS TC 65 80 amp 110 TRANSFER CASE Front Drive When traveling through sand loose dirt mud snow or ice or when ascending grades where the rear wheels might spin shift to front wheel drive for better traction Shift before the truck is in trouble Engagement and disengagement of the front axle can best be made while the engine is pulling lightly It can be shifted at any speed provided the rear wheels are not spinning An indicator switch is actuated when the shifter shaft is in the engaged position Underdrive TC 65 only When slow positive pulling power is desired shift to underdrive Underdrive may be used to obtain a convenient combination with third or direct for climbing some grades The transfer case should be shifted between high and low range only when the truck is stopped Power Take Off If the transfer case is equipped with a power take off or a PTO mounted hydraulic pump it can be operated while the vehicle is moving or stationary To engage vehicles fitted with an automatic transmission put transmission and transfer case in gear apply the brakes and shift the PTO or hydraulic pump into the engaged position while the engine is idling After the PTO has been engaged shift the transmission and transfer case to the desired gear An indica
13. ar onto splines of the lower shaft next to spacer sleeve Secure de clutch gear to shaft with the washer and locknut Tighten to correct torque Stand the shaft upright on the declutch gear Slide the clutch collar over the shaft and allow to set on the roller bearing Slide the clutch gear onto the raised teeth of the shaft Be sure the jump lock is facing up or toward the end of the shaft where the direct drive gear will be located see fig 8 Liberally grease the inside diameter of the direct drive gear and outside diameter of the needle bearing race Place the direct drive gear thrust washer 148 thick on a bench and place the direct drive gear on top of the washer side of gear with clutch teeth to be against washer Place needle bearing race inside the gear with the bearing race lock pin nearest the top of the gear Grease needle bearings and install one row of needle bearings see input shaft assem bly note at a time between gear and race Install a spacer ring after each row Slide this assembly onto the shaft with the clutch teeth of the gear facing down Align the pin in the groove and push the gear as far as possible onto the shaft Press the roller bearing cone assembly onto the bearing adapter tube Install this assembly onto the rear of the output shaft by tapping with a soft hammer Check thrust clearance as on input shaft 015 020 Set shaft aside for assembly into the front half of the main ho
14. aulic lines can be disconnected and the pump can be detached after the transfer case has been removed from the vehicle Position a transmission jack of suitable capacity beneath the transfer case 800 Ib transfer case Be sure that the transfer case is seated safely on the jack Disconnect transfer case mountings at rubber insulators Since mountings vary consult the vehicle service manual Check to ensure that all mountings and connec tions to the transfer case have been disconnect ed Lower the transfer case to the floor and remove from under the vehicle It may be necessary to jack the vehicle up to allow room to remove the transfer case B 10 Installation into Vehicle Place transfer case on transmission jack and position jack and transfer case under the vehicle Raise transmission jack and position transfer case Connect transfer case mountings Since mount ings vary consult the vehicle service manual Connect drivelines Connect shift cylinder air lines to air cylinders Install hydraulic pump to transfer case if it is not already Connect indicator light lead wires to terminals Fill transfer case housing with appropriate lubri cant to the correct level and install fill plug Refer to lubrication Section Il Road test the vehicle by driving slowly with no load for the first few moments then test at a higher speed listening for any problems Check transfer ca
15. bearings and uses spacers of 360 to 385 thickness in 005 increments 23 Install drive flange seal with an appropriate driver 24 Coat the flange hub with gear lubricant Install drive flange onto output shaft with nut and lock washer Tighten nut to correct torque 25 Apply gasket to housing assembly and install declutch carrier with eight capscrews tighten ing to correct torque Declutch carrier must be installed so oil seal drain passage is to the bottom of the case see fig 32 G Shift Cylinder Assembly and Adjustment 1 Screw adjusting bolt on adjustment cap located at input front side of case in until the bolt stops 2 Install two O rings onto shift cylinder adapter tube coat adapter tube with gear lubricant and install tube into rear of housing see fig 33 3 Place small O ring over threaded end of shift shaft and against shift shaft shoulder 4 Place spring over end of shift shaft and into adapter Place plastic stop ring over spring NOTE PTO 110 does not have springs but has two plastic stop rings one on each side of piston 5 Place piston over shift shaft with the shallower of the two grooves toward the shaft Make sure small O ring on shaft is seating in chamfer in piston bore Depress the spring with the piston and secure piston with the washer and locknut Tighten locknut to correct torque Place an oil soaked felt wiper in shallow groove on piston and an O ring in the deep groove see
16. ck over front of shaft and onto the raised teeth of shaft Slide spacer ring 131 35 thick over front of shaft and onto the raised hub portion of the shaft past the splines The inner diameter chamfer of the spacer is to face the direct drive gear Set the input shaft aside for installation into the front half of the main case Refer to part E page 16 for this assembly Be sure to hold the front spacer ring as the shaft is dropped into the front of the case so the parts do not slide from the shaft Intermediate Shaft Assembly TC 65 amp 80 see fig 10 and fig 11 1 Tap direct drive gear woodruff key into the slot located in the center of the shaft Heat direct drive gear in oil or in an oven to 200 F 93 C Press the shaft into the gear by placing the front of the gear coned side on a metal tube and applying pressure to the rear of the shaft Be sure the woodruff key is mating properly with the slot in the gear TC 65 only Slide the spacer ring 333 thick over front of shaft and against direct drive gear TRANSFER CASE ASSEMBLY Tap underdrive gear woodruff key into the slot Heat underdrive gear in oil or in an oven to 200 F 93 C and press the shaft into the gear by placing front of the gear flat side on a metal tube and applying pressure to the rear of the shaft Be sure the woodruff key is mating proper ly with the slot in the gear TC 80 only Slide gear spacer 315 3 long ove
17. ct all spacer washers and rings for wear The width or thickness of each spacer washer or ring has been noted in the assembly procedures and each spacer should be measured with a micrometer for proper size Worn spacers should be replaced 8 The clutch collar shift fork slot is offset which is indicated in Fig 5 The long side can be deter mined by examining the collar for the external short extended hub This short hub referred to in the assembly instructions must always face the mating gear clutch teeth whether in the de clutch housing PTO housing or main case B Input Shaft Assembly TC 65 amp TC 80 Short hub always faces mating clutch teeth Fig 5 TC 65 Input Shaft Assembly with Blanking Sleeve Fig 6 TC 65 Input Shaft Assembly with PTO Gear Fig 7 TC 80 Input Shaft Assembly with PTO Gear es TRANSFER CASE ASSEMBLY B Input Shaft Assembly continued TC 65 amp TC 80 See Fig 5 6 and 7 1 Place input shaft thrust washer 148 thick on bench Liberally grease inside diameter of direct drive and outside diameter of needle bearing race Place front of direct drive gear side of gear with clutch teeth on thrust washer Place needle bearing race inside the gear with the bearing race lock pin facing the rear of the gear or up Grease needle bearings and install a row of needle bearings between gear and race NOTE Install 62 needle bearings only in each row One extra needle can b
18. d rear roller bearing cone 2 Press front bearing from shaft if necessary H Output Shaft Disassembly TC 65 amp TC 80 1 Press shaft from the direct drive gear by placing the front of the gear on a metal tube and apply pressure to the rear of the output shaft Remove the roller bearing bearing adapter tube direct gear and related parts from the shaft 2 Press the roller bearing cone from the bearing adapter tube if necessary 3 Remove locknut and washer from the declutch gear and remove declutch gear Discard locknut and replace with a new locknut at assembly Slide spacer sleeve from shaft If necessary press roller bearing cone from the hub of the declutch gear TC 110 1 Slide direct drive gear spacers and remaining parts from shaft 2 Remove the locknut and washer from the declutch gear and remove declutch gear Dis card the locknut and replace with a new locknut at assembly Slide spacer ring from rear of shaft If necessary press roller bearing cone from the hub of the declutch gear 3 If inner race and inner thrust washer are not worn or damaged do not remove If replacement of either is required the inner race must be ground hacksawed or torched off taking care not to damage the shaft itself The inner race cannot be removed without destroying it 10 IV TRANSFER CASE DISASSEMBLY Oil Pump Disassembly 1 Place pump in a vise shaft facing up so that one jaw grips across two ports
19. de two roller bearing assemblies and spacer ring over the roller bearing inner race located at the rear of the shaft Grease the roller bearing assemblies and the inner diameter of the direct drive gear Slide the gear over the rear of the shaft Place the gear spacer ring 5 5 thick over the rear of the shaft and against the gear Oil groove side of washer must face gear Install flange washer and nut and torque to specifica tion Check clearance as in input shaft assembly 015 020 clearance Remove nut washer and flange 6 Set the shaft assembly aside for installation into the front half of the case Fig 14 TC 110 Output Shaft Assembly E Main Housing Assembly NOTE Housing halves are matched at the factory and should be replaced as pairs only 1 Install bearing cups into each half of the main housing Install bearing cup into the bearing cup adapter and tap assembly into housing bore for Assemble seal carrier to front half of housing with six bolts Be sure to align oil passage and grooves Tighten bolts to correct torque Assemble intermediate shaft front cap to front half of housing with nine bolts Tighten bolts to correct torque Six bolts for 110 only Place an O ring into the groove of each shift adjustment cap Smear lubriplate or grease all around the O ring and install into the housing securing with 4 bolts for each cap NOTE The PTO 110 does not use shift ad justment caps Install a jam nut on
20. ders Withdraw shift fork and clutch collar see fig 3 Remove six capscrews holding declutch hous ing to main case Remove the declutch housing by tapping it with a soft hammer loosening it from the main case Remove shims and retain with housing for later use at assembly Remove companion flange lock nut and washer from carrier and output shaft assembly discard ing nut Use a new nut for reassembly Slide companion flange off output shaft To press output shaft from declutch carrier and clutch gear press against threaded end of shaft while supporting by the clutch gear Remove output seal bearings and end play spacer from declutch carrier discarding seal Remove bearing cups from the declutch carrier only if they are to be replaced Fig 1 Fig 3 F IV TRANSFER CASE DISASSEMBLY Splitting the Main Housing Remove the declutch and PTO assembly if so equipped from the transfer case see part D this section Remove the top input flange locknut and washer and remove flange from shaft Discard locknut and replace with a new locknut at assembly Re move bolts from seal carrier and remove seal carrier from case Remove seal from carrier if re placement is necessary If the transfer case is a two speed TC 659 remove the speedometer driven gear and adap ter from the speedometer gear and seal carrier The lower rear output flange may now be re moved after the locknut and washer have b
21. e packed into each row but this makes the rollers too tight invaria bly causing rubbing heating and eventual failure of the bearing pack gear and shaft Install a spacer ring tap the needle bearings and spacer ring against the shoulder of the race with a punch and install next row of bearings Place gear spacer ring 3 8 thick on top of gear assembly with chamfered inside diameter facing inside of gear Two speed case only TC 65 Grease inside diameter of underdrive gear and outside diameter of needle bearing race Place needle bearing race on the bench with the flange facing down Place underdrive gear onto the race with the clutch teeth facing up Grease needle bear ings and install a row of needle bearings be tween gear and race NOTE Install 62 needle bearings only in each row One extra needle can be packed into each row but this makes the rollers too tight invaria bly causing rubbing heating and eventual failure of the bearing pack gear and shaft Install a spacer ring tap the needle bearings and spacer ring against the shoulder of the race with a punch and install next row of bearings Two speed case only TC 65 Install the front side of the input shaft short journal through the underdrive gear assembly The flange of the underdrive gear inner bearing race is to face the front of the shaft and the clutch teeth of the gear are to face the center of the shaft Align the inner race lock pin with
22. een removed Discard locknut and replace with a new locknut at assembly Remove bolts from speedometer gear and seal carrier TC 65 or seal carrier TC 80 and TC 110 and remove car rier Remove seal from carrier if replacement is necessary Remove bolts from the intermediate shaft rear and remove cap Remove shims and retain with cap for later use at assembly Remove oil pump from cap for further disassembly see part this section If the transfer case is not equipped with a PTO remove the bolts from the input shaft rear cap and remove the cap Remove shims and retain with cap for later use at assembly The case should now be supported by the front half and be positioned so that the rear half of the case is facing upwards Mark the housing halves as a set as these must be reassembled together Remove all the bolts that hold the housing halves together and lift off the rear housing half see fig 4 The three shafts can now be lifted out of the front half of the case NOTE The stationary shifter shafts or neutral gear range shifter shafts will have to be removed with the input and output shafts Input Shaft Disassembly TC 65 1 Slide underdrive gear needle bearings and needle bearing race from front of shaft If neces sary lift underdrive gear from needle bearing race Collect the needle bearings and spacer ring and place into a container 2 Side clutch collar and clutch gear from shaft
23. lide front input companion flange onto the splines start flange into the front bearing cone inner race and secure flange with washer and locknut Tighten locknut to correct torque see fig 23 Tap output shaft down to seat the shaft into the bearings and related parts Place the declutch housing into the output shaft front housing bore Measure with feeler gauges the amount of clear ance between declutch housing and main housing Add 005 to this dimension and add the necessary shims to match the calculated dimension Assemble declutch housing to main housing and secure with the proper bolts Tight en bolts to correct torque See Part F this sec tion for declutch assembly Turn housing over to position rear of housing face up Place an O ring into the shift adjust ment cap s and insert into rear half of housing Secure with four bolts for each cap Assemble a jam nut loosely on each adjusting bolt and screw the bolt into the adjustment cap s Adjust non movable shift shafts by running the bolt at the back of the case outward until it protrudes at least 1 inches Turn the front bolt inward until the shaft meets resistance then back it out turn and lock it Turn the back bolt inward until it meets the shift shaft then back it out turn and lock it Check for binding by turning the shafts See section VI G for shift shaft adjustment Install oil pump if equipped and gasket to rear intermediate shaft cap if oil pum
24. lide the spacer rings and clutch collar from the front of the shaft 2 Remove the locknut and washer from the rear of shaft and using a puller in the groove provided remove the blanking sleeve from shaft Discard locknut and replace with a new locknut at assembly The direct drive gear and remaining parts can now be disassembled 3 If inner race and inner thrust washer are not worn or damaged do not remove If replacement of either is required the inner race must be ground hacksawed or torched off taking care not to damage the shaft itself The inner race cannot be removed without destroying it 4 If necessary remove the roller bearing cone from the blanking sleeve G Intermediate Shaft Disassembly NOTE Intermediate shaft gears are a tight press fit on the shaft Disassembly is not advised unless there is damage to shaft or gears and replacement is necessary TC 65 1 Heat the gears evenly and carefully to 200 F 93 C using temperature marker to determine 2 Press the underdrive gear off the shaft first and remove the key This will allow the direct drive gear and spacer to be pressed off IMPORTANT Do not attempt to press both gears off at one time Damage to the shaft gears and the press may result TC 80 1 Heat the direct drive gear as for the TC 65 above and press off the shaft TC 110 HEATING IS NOT REQUIRED FOR REMOVAL OF THE INTERMEDIATE SHAFT GEAR 1 Press shaft from the gear an
25. nd without bind ing Rotor end play of 003 010 can be ob tained by adding or removing cover plate gaskets Secure oil pump and gasket to rear intermediate shaft cap TRANSFER CASE ASSEMBLY Final Assembly 1 23 Attach all mounting brackets that must be secured to the transfer case before the case can be installed in the truck Install temperature sensor if vehicle is so equipped Prior to plumbing prime oil pump and fill filter cup with oil can Connect oil pump lines Refer to Section Part B and install transfer case into vehicle TORQUE SPECIFICATIONS Location Air shift cylinder attach bolts Declutch housing inspection plate bolts Declutch to case bolts Front drive PTO pump carrier unit and all end cap bolts Transfer case housing bolts Flange retaining nuts and declutch gear retaining nuts TC 65 and 80 Flange retaining nuts TC 110 amp TC 80 Transfer case mounting angle attach bolts Torques given apply to parts coated with machine oil For dry parts increase torque 10 24 Bolt Size 14 20 varies Hexagon Head 1 4 20 x 1 HH 7 14 x 21 HH 7 1g 14 17 HH 7 14 x 23 4 HH 1 5713 x 13 4 12 point 11 4 18 11 gt 18 Hex 3 4710 x 115 HH 60 60 95 325 400 265
26. nt pattern 12 TRANSFER CASE ASSEMBLY A General Precautions for Reassembly IMPORTANT Read this section before starting reassembly procedure Make sure that the interior of the transfer case is clean It is important that dirt be kept out of transfer case during reassembly Use certain precautions as listed below during reassembly 1 Gaskets Clean all gasket surfaces of past gasket material Use new gaskets throughout the transfer case as it is being rebuilt 2 Bolts To prevent oil leakage use Permatex Form A Gasket 2 pliable setting sealant or equal on all threads See torque specifications for recommended torque Section VII 3 Assembly Refer to the exploded views in the parts manual Section VIII as a guide to reas sembly 4 Initial Lubrication Coat all thrust washers splines and seals with lubriplate during installa tion to provide initial lubrication preventing scoring and galling 5 Bearings Press or drive bearing races by applying force to inner race or outer race whichever is being installed 6 Universal Joint Companion Flanges Pull the companion flanges tightly into place with the locknuts old locknuts may be used for pulling then replaced with new tighten to proper torque Failure to pull the flange tightly into place will not seat the bearings properly caus ing erroneous end play readings and possible damage to bearings shafts and gears 7 Inspe
27. p has been removed TRANSFER CASE ASSEMBLY F PTO and Declutch Assembly 8 Place piston over threads of shift shaft depres sing spring with shallower of two grooves facing towards shaft Fig 29 NOTE The PTO and declutch assemblies are similar except for the manner in which the housings are bolted to the transfer case See fig 24 and 25 for mounting of appropriate housing 1 Bolt PTO declutch housing and gasket to main case with six capscrews Be sure to align oil pas sages see fig 24 Tighten capscrews to correct torque 2 Slide clutch collar into the shift fork ears and assemble the two parts together into the de clutch housing see fig 26 The short hub on the collar must face the housing and the flat side of the fork must face away from the housing The shift fork is not symmetrical and it is possible to install it backward Even if the shaft and adapter will assemble the fork will interfere with the inside of the declutch housing and cause incom plete or erratic shifting 3 Install shift shaft through shift fork and into de clutch housing Align two grooves in shaft with clamping screw holes 4 Install two shift fork clamping screws and tight en to correct torque Secure clamp screws with lockwire see fig 27 NOTE If the clamping screws are not easily accessible through the side cover as shown in fig 27 the fork is installed backward 5 Install O rings in adapter tube and insert adapte
28. pscrews evenly to prevent cocking the cylinder cap 14 Apply cover plate gasket to declutch housing 15 Install cover plate with four capscrews tighten ing to correct torque 16 Insert plunger into indicator switch hole with rounded side of plunger against the shift shaft 17 Install indicator switch shimming with copper washers as necessary for proper operation Check with continuity indicator 18 Press bearing cups into declutch carrier 19 Install snap ring on output shaft and slide clutch gear onto output shaft Flat side of gear to face up see fig 30 Fig 30 Fig 31 21 21 Place end play spacer through front of declutch carrier and on top of inner roller bearing 22 Press outer roller bearing onto output shaft and into declutch carrier NOTE The declutch and PTO output shaft bearings need no adjustment as the bearing spacer is factory selected for proper end play If the bearings have been replaced assemble the output shaft in its carrier with output flange installed torque the output flange nut to specification and check the end play Use a 323 thick spacer for the first check Experience has shown that this gives the proper end play in 75 of assemblies the first time If it is more than 005 inch or less than 003 inch substitute a spacer with another thickness and recheck Spacers of 313 318 323 and 328 inch thickness avail able The PTO 110 has different
29. r front of shaft and against direct drive gear Place spacer ring 5 5 thick over front of shaft and against gear spacer Fits on smallest hub Inner diameter chamfer of ring to face gear Press roller bearing cone onto the front of the shaft Press roller bearing cone onto the rear of the shaft Set the shaft assembly aside for installation into the front half of the main housing Refer to part E page 15 for this assembly Fig 10 TC 65 intermediate Shaft Assembly Fig 11 TC 80 intermediate Shaft Assembly 15 VI C Intermediate Shaft Assembly continued TC 110 Fig 12 TC 110 intermediate Shaft Assembly Slide spacer ring over the rear of the shaft and against the shoulder of the shaft with the inside chamfer facing toward the center of the shaft Slide gear over the splines on the shaft Press rear roller bearing cone over the rear of the shaft Press front roller bearing cone over the front of the shaft Set the shaft assembly aside for installation into the front half of the main housing Refer to Part E page 16 for this assembly Fig 13 TC 65 and 80 Output Shaft Assembly TRANSFER CASE ASSEMBLY D Output Shaft Assembly TC 65 amp TC 80 See fig 13 1 Press tapered roller bearing cone onto the de clutch gear hub Slide spacer sleeve over the shaft short journal and against the raised teeth of the shaft Slide declutch ge
30. r tube into declutch housing see fig 28 6 Place small O ring over threads of shifter shaft 7 Place stop ring over shift shaft and place spring over end of shift shaft NOTE The PTO 110 does not have a spring But has two plastic stop rings one on each side of the piston Fig 24 Declutch Housing to Transfer Case Location Fig 27 20 TRANSFER CASE ASSEMBLY 9 Install shift shaft nut and washer Tighten nut to 20 Press roller bearing onto output shaft and insert correct torque declutch carrier onto output see fig 31 10 Place an oil soaked felt wiper in shallow groove O RING on piston and an O ring into deep groove see DEEP GROOVE fig 29 2 it tak time t k the felt UA Since it takes some time to soak the fe wiper long enough to expand and soften enough gt SHALLOW GROOVE to fill the groove it is a good idea to do this ahead SHIFT SHAFT NUT of time Also the felt wiper will not necessarily fill the groove the entire circumference of the e 7 a SHIFT SHAFT piston 11 Coat the shift cylinder tube lightly with gear lub 22 ricant Place cylinder tube over piston and over Ih adapter tube Use care not to cut or displace O u rings pi x M miim 12 Install O ring in shift cylinder cap B SMALL O RING 13 Install cylinder cap on cylinder tube with four b d long capscrews tightening to correct torque SHIFT PISTON Tighten ca
31. se for leaks around gaskets and seals TRANSFER CASE DISASSEMBLY General Precautions for Disassembly IMPORTANT Read this section before starting the disassembly procedures It is assumed in the disassembly instructions that the lubricant has been drained from the transfer case and the transfer case has been removed from the chassis Follow each procedure closely in each section mak ing use of both tests and pictures Refer to the ex ploded views located in Section VIII as an aid in dis assembly 1 The outside of the unit should be cleaned before starting the disassembly If steam cleaning ensure that breather and air fittings are covered to prevent water from entering assembly Cleanliness Provide a clean place to work It is important that no dirt or foreign material enters the unit during repairs Position the transfer case in a stand suitable to support the transfer case A specially fabricated stand that can rotate the case is extremely use ful Assemblies When disassembling the various assemblies lay all parts on a clean bench in the same sequence as removed This procedure will simplify reassembly and reduce the possibility of lost parts Bearings Carefully wash and relubricate all bearings as removed and protectively wrap until ready for use Remove bearings with pullers de signed for this purpose or in a manner which will not damage those bearings that will be re
32. stop ring from the shift shaft or from the shift cylinder adapter tube located in the housing Remove shift cylinder adapter tube from hous ing Discard O rings from the adapter if replace ment is necessary 10 11 12 13 14 IV TRANSFER CASE DISASSEMBLY PTO and Declutch Disassembly The declutch assembly and PTO are essentially identical Hereafter reference will be made to the declutch only For cases equipped with PTO use the instructions for declutch disassembly inspection and reassembly exactly as given Remove eight capscrews holding declutch car rier to declutch housing Tap carrier to loosen and withdraw carrier and output shaft assembly see fig 1 Unscrew indicator light switch from declutch housing and remove spacer washers Remove switch actuator pin from inside declutch hous ing using a magnet or turn upside down and dump it out Remove four capscrews from declutch cover plate and remove cover plate Cut the lockwires and remove the shift fork clamping screws see fig 2 Remove four long capscrews from shift cylinder and lift off cylinder cap Withdraw shift piston and shift shaft as a unit Remove shift cylinder adapter tube and stop ring discarding O rings Remove nut from shift shaft and lift off the piston and spring discarding O rings and felt wiper NOTE There are two plastic stop rings and no spring in the PTO 110 cylin
33. the elongated groove in the journal and slide gear on all the way With inner race pressed tightly against inner thrust washer check with a feeler gauge for 015 020 clearance between gear hub and thrust washer For ease in assembly use a companion flange from the transfer case as a stand for the shaft Slide the flange onto the front of the shaft and stand the shaft upright Slide the clutch gear onto the raised teeth of the shaft The jump lock portion of the teeth see fig 8 are to face the 14 rear of the shaft Slide the clutch collar onto the teeth of the clutch gear The side of the collar with the short hub is to face the rear of the shaft see fig 5 Place direct drive gear assembly including gear spacer ring and thrust washer over the shaft aligning inner race lock pin with elongated groove in shaft and against the clutch gear The clutch teeth of the gear must face the front of the shaft Press the bearing cone over the blanking sleeve hub and slide the sleeve over the shaft splines and secure with the washer and locknut Tighten nut to correct torque Check thrust washer clearance as above 015 020 Set the shaft aside for installation into the front half of the main case Refer to Part E page 16 for this assembly Remove the flange from the shaft that was used to support the shaft during assem bly making sure to retain underdrive gear needles and inner race in position Fig 8
34. to each adjusting bolt and start the adjusting bolt into each cap Position front half of housing with the inside facing up the intermediate shaft located in the front half of Fig 16 the main housing TC 65 amp 80 only 2 TRANSFER CASE ASSEMBLY 6 Reassemble the shift fork and shift shaft assem 11 TC 65 only Press seal into output shaft rear seal bly if it has been disassembled Place the proper speedometer gear carrier Assemble gasket and shift fork onto the clutch collar on the input and carrier to housing with six bolts Be sure to align output shafts 7 Place input shaft front bearing cone into bearing race Place the input shaft intermediate shaft and output shaft assemblies into the front half of housing in that order see fig 16 TC 110 only Place roller bearing on rear of out put shaft 8 Install main housing gasket with sealer and place rear half of main housing over shaft assemblies and onto the front half guiding shift rails through bores see fig 17 Secure two halves together with the shoulder bolts and 12 point capscrews Tighten bolts to correct torque 9 Tap input shaft down to seat the shaft into the bearings Place the PTO housing or rear cap into the input shaft rear housing bore Measure with feeler gauges the amount of clearance between the cap and the housing see fig 18 and 19 Add 005 to this dimension and add the necessary shims to match that calculated dimension
35. tor switch is actuated when the shifter shaft is in the engaged position To disengage the PTO or hydraulic pump shift the transmission to neutral manual or automatic allow the machinery to come to rest then shift the control to disengage LUBRICATION Recommended Lubricants On Highway Vehicles Type Grade Temperature MIL L 2104 SAE 50 Above 10 F Heavy Duty Engine Oil SAE 30 Below 10 F Mineral SAE 90 Above 10 F Gear Oil SAE 80 Below 10 F MIL L 2105 SAE 90 Above 10 F Oil except Sulfur chlorine lead type SAE 80 Below 10 F Heavy duty engine oil Make sure to specify heavy duty type meeting MIL L 2104 specifications Mineral gear oil inhibited against corrosion oxidation and foam Off Highway amp Mining Equipment Type Grade Temperature MIL L 2104 SAE 50 Above 10 F Heavy Duty Engine Oil SAE 30 Below 10 F Special Recommendation For extreme cold weather where temperature is consistently below O F MIL L 2104 SAE 20W Below O F Heavy Duty Engine Oil LUBRICATION NOTE Oil Change and Inspection Recommendations The oil change and inspection periods described below are based on the average use and operating conditions the transfer case may encounter It is recommended that the individual owner make a periodic lab analysis of the lubricant to determine contamination based on the individual s own operating conditions With this data the individual owner can
36. ug Replace fill plug and examine transfer case for leaks around plugs and gasket sealed areas Do not overfill the transfer case D Inspection Gear oil level 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 Operating Temperature The operating temperature of the transfer case should never exceed 250 F 120 C Extensive Operation at temperatures exceeding 250 F will result in rapid breakdown of the oil and shorten the transfer case life F Shift Cylinder Inspection With every oil change the air shift cylinder lines and valves should be inspected for leaks and possible malfunctioning Low pressure conditions can cause partial clutch tooth engagement which may result in gear jumping and premature wear TRANSFER CASE REMOVAL AND INSTALLATION Removal from Vehicle Remove fill and drain plugs and drain lubricant Disconnect indicator light wires Disconnect the air shift lines Be sure to tag the lines for future identification Disconnect the speedometer cable if it is so equipped Disconnect drivelines at flanges If the transfer case is equipped with a PTO mounted hydraulic pump remove the four mounting bolts slide the pump out of the trans fer case and secure pump to the frame and out of the way NOTE If it is desired the hydr
37. using Refer to Part E page 16 for this assembly TC 110 See fig 14 1 16 If the inner thrust washer and needle bearing inner race have been removed from the rear of the output shaft place the thrust washer 148 thick over the shaft and against the raised teeth of the shaft Oil groove side of washer must face outwards and toward where the direct drive gear will be placed Heat the inner race in an oven to about 200 250 drop over shaft and tap down to inner thrust washer with a suitable driver the roller bearing inner race must be snug against the inner thrust washer TRANSFER CASE ASSEMBLY 2 Slide spacer ring 13 5 thick over front of 2 Press a new seal into the input shaft seal carrier shaft and onto the raised hub portion of the shaft past the splines The inner diameter chamfer of the spacer is to face the center of the shaft 3 Press the roller bearing cone over the hub of the 3 declutch gear Slide the declutch gear onto the splines located at the front of the shaft Secure declutch gear to shaft with the washer and lock nut Tighten locknut to correct torque 4 4 Slide spacer ring 21 3 gt thick over rear of shaft and onto the raised teeth of the shaft not used 110 Slide clutch collar over the rear of the shaft and over the raised teeth of the shaft Short hub side of collar see fig 5 to face toward where the direct drive gear will be placed 5 Sli
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