TC-180 Service Manual - Fabco Automotive Corporation
Contents
1. SERVICE MANUAL 7 TORQUE SPECIFICATIONS 10 FI LBS 30 FT LB5 10 185 800 FT LBS l 10 FT LBS LIS lt 3 5 e 554 NNj 70 FT LBS 10 FT LBS 22210 Ex B M E x b HZ 10 FT LBS NI 7 qu 15 FT LBS NU 800 FT LBS TA 4 PN 4 a o 1 m 1 litt 800 FT LBS 800 FT LBS 10 FT LB 19 FT LBS 625 0540 ALL TORQUE LB FT VALUES ARE FOR DRY UNLUBRICATED THREADS AND SHOULD BE WITH IN 10 OF THE VALUES SHOWN Figure 100 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 50 FT LBS 625 0540 A TO FT LBS TO FT LBS 800 FT LBS omni TO FT LBS 800 FT LBS UM gt gt f AA 70 FT LBS ts 70 5 1 ANY oL m 15FT LBS SOM ELES ASAAN ma il E 2 5 M ee Ip a ine 800 FT LBS 800 FT LBS TO FT LBS 70 FT LBS ALL TORQUE LB FT VALUES ARE FOR DRY UNLUBRICATED THREADS AND SHOULD BE WITH IN 10 OF THE VALUES SHOWN Figure 101 Fabco Automotive Corporation Liv2. 8 Install the declutch housing cover with a new gasket Torque the four cap screws to specification See Figure 88 Figure 88 9 Slip the air shift cylinder into position over the piston Install a new O ring on the shift cylinder cap and insert into the cylinder See Figure 89 Figure 8 625 0540 A 10 Secure the assembly with the four long cap screws Torque to specification See Figure 90 Figure 90 11 Insert the indicator switch actuation into place The rounded end of the pin must face inward See Figure 91 Figure 91 12 Install the switch using a new copper washer Torque to specification See Figure 92 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL Figure 92 13 Using a new gasket and eight cap screws install the front output shaft assembly to the declutch housing Torque to specification See Figure 93 Figure 93 6 6 4 INPUT SHAFT INSTALLATION Figure 94 625 0540 A 1 Position the transfer case with its rear end facing upward 2 Insert the rear bearing cup into the bore on the housing Use the original shim pack See Figure 95 Figure 95 3 Align and install the PTO declutch housing or cap on to the transfer case housing See Figure 96 Figure 96 4 Install the six 12 point cap screws and torque to specification 5 Rotate t
3. SERVICE MANUAL 625 0540 A 5 4 INPUT SHAFT REMOVAL 5 5 REAR OUTPUT SHAFT REMOVAL Input Shaft e i DE k E ASS d Figure 11 lf PTO declutch housing cap has been removed also remove shim pack on rear side Keep the shims together with the PTO declutch housing or cap to facilitate reassembly Carefully rotate the TC over so that the front side is facing upward The input shaft can slide downwards as it has some play between the housing and the gear and it is only held by the bearing cup that is no longer constraint by the PTO declutch housing or cap Remove the ten cap screws and washers securing the front input carrier to the housing Remove the input carrier and shaft assembly by lifting on the shaft yoke Discard the gasket LJ Rear Output Shaft Figure 12 Position the transfer case with its rear end facing upward Remove the ten cap screws and washers securing the rear output carrier to the transfer case housing Mark the position of the carrier to housing with chalk as it needs to be reassembled in the same position Remove the carrier and shaft assembly by lifting on the shaft yoke Discard the gasket See Figure 13 Figure 13 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVI
4. 625 0540 A 3 0 CLEANING AND INSPECTION 3 1 CLEANING Steam may be used for external cleaning of completely assembled units Care must be taken to ensure that water is kept out of the assembly by sealing breather caps and other openings The transfer case housing which is too large to conveniently clean with solvents may be immersed in a hot solution tank containing a mild alkaline solution Aluminum parts such as the carriers caps declutch housing and air shift cylinder components must never be cleaned in any type of alkaline solution Parts clean in a hot solution tank must be rinsed thoroughly to prevent damage by traces of alkaline material Parts with ground or polished surfaces such as bearings gears shafts and oil pump components should be clean with emulsion cleaners or petroleum solvents An alkaline solution may damage the machined surfaces and such cleaning methods should be avoided 3 2 DRY 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 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 3 3 INSPECTION Prior to reassembly parts which are to be reused must be carefully inspected for signs of wear or damage Replace
5. SERVICE MANUAL 625 0540 A 6 Rotate TC over so that its rear is facing upward To prevent damage reach in the case and support the intermediate shaft assembly as the unit is rotated 7 Slip the spacer washer over the intermediate shaft against the gear Heat and install the remaining bearing cone assembly against the spacer washer See Figure 73 Figure 70 3 Quickly lower the intermediate shaft assembly through the gear Be sure that the gear is firmly seated against the shaft shoulder 4 Place one of the bearing cups into its bore in the front of the housing Install the front intermediate shaft cap with a new gasket See Figure 71 Figure 73 8 Place the bearing cup into its bore Install the rear cap with the original shim pack See Figure 74 Figure 71 5 Install the six cap screws and washers Torque to specification See Figure 72 Figure 74 9 Install the six cap screws and washers Torque to specification 10 Rotate transfer case over such that its shafts are horizontal Mount a dial indicator such that the indicator tip rests against the end of the shaft See Figure 75 Figure 72 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com 11 12 6 6 2 REAR OUTPUT SHAFT INSTALLATION Rear Output Shaft without Neutral Figure 75 Pry the gear up and down several times to be sure
6. 866 0888 3 E Huppa E Figure 106 Fabco Automotive Corporation Livermore Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A 1 gt gt v AL d nj HATEMIM HEAT TMEATMENT F rH LEED OIL SEAL 32 8166 H HARP HPM DRIVER SEAL ead Q7 TORT 151 L amp wREHCE S455 H i h T Figure 107 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A oe ELA Wa lt 2 4 2 1 9 06 866 0751 SETUP SLEEVE REAR OUTPUT SHAFT Figure 108 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com
7. bearing See Figure 58 625 0540 A P Figure 58 Start creating the shift fork assembly sliding shift fork onto the shorter side of the shifter shaft Place a flat washer on top of the fork and screw in a locknut using Loctite 272 or equal See Figure 59 Figure 59 Place an O ring on the 3 8 threaded side of the shifter shaft and attach the shift fork assembly onto the clutch collar See Figure 60 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL Figure 60 10 Press the bearing cup into the carrier See Figure 61 Figure 61 11 Place an O ring into the insert on the carrier See Figure 62 Figure 62 _ 625 0540 A 12 Use Loctite 620 or equal on the outer diameter of the oil seal and press it into the carrier See Figure 63 Figure 63 13 Align the carrier and place it on top of the bearing cone Grease up the area between the shift shaft and the carrier 14 Place a nylon washer on to the shift fork assembly Soak the felt strip in gear oil and install it in the inner groove of the piston Slip an O ring around the outer groove before sliding it onto the nylon washer The end of the piston with the counterbore should be facing outward Place a washer on top of the piston and screw in a locknut using loctite 272 or equal Place another nylon washer above the piston Put an O ri
8. TC 180 Transfer Case SECTIONAL VIEW Figure 2 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A i apt SON 77 77 Ss RI 7A MEE and _ Es es FRONT s WE DEAR x AXLE Lan ut f DOMI 9 lt lt lt 4444 2 M jh EY STET S 2 180 Transfer Case with Upper Rear PTO SECTIONAL VIEW Figure 3 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A 2 0 LUBRICATION 2 1 RECOMMENDED LUBRICANTS SAE 50 synthetic is recommended for on off highway operation NOTE EXTREME PRESSURE EP OILS ARE NO LONGER RECOMMENDED FOR USE IN FABCO TRANSFER CASES UNDER CERTAIN OPERATING CONDITIONS THESE OILS MIGHT FORM CARBON DEPOSITS ON GEARS AND SHAFTS 2 2 INSPECTION The oil is to be maintained at the level of the fill plug at all times Check at the following In
9. and supported with the appropriate frame stands or very secure blocking WARNING NEVER WORK UNDER A VECHILE 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 and axle support dollies etc weight of Fabco components is given in the front of the applicable service manual 4 Caution must be exercised when cleaning the component or underside of the vehicle Compressed air should not be used to blow dirt away as any harmful contaminant material on the bottom of the vehicle will be spread around the work area Appropriate solvents and cleaning solutions can be used in accordance with their labeling instructions or by referring to the Material Safety Data Sheet MSDS that is available for each cleaner Approved protective eyewear gloves masks and clothing should always be worn 1 4 2 ASSEMBLY PRECAUTIONS Read these instructions completely before starting reassemble Refer to the appropriate exploded view in the parts manual All parts must be cleaned The gasket surfaces must be free of oil gasket material Do not reuse old gaskets Bearing cups bores shaft splines and bearing mounting surface should be coated with Lubriplate or equivalent This is necessary to reduce the possibility of galling All used oil seals must be replaced and the new oil seals should be coated w
10. designs vary consult vehicle service manual Connect the drivelines the speedometer cable and the shift cylinder air lines Connect the indicator light and temperature sensor wires Fill the housing with the appropriate lubrication to the correct level and install the oil fill plug Road test the vehicle and check the transfer case for leaks around seals and gaskets NOTES Fabco Automotive Corporation Livermore Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A 5 0 DISASSEMBLY Disassembly and assembly of the TC 180 Transfer Case with PTO is a relatively simple procedure which be made easier by the use of some very simple tooling Details of all tooling required are given in the tooling section 9 0 for manufacture in your own facilities or Automotive may be contacted for a price and availability 5 1 GENERAL DISASSEMBLY 1 After removing the transfer case from the vehicle thoroughly clean the exterior 2 Remove the drain plug and drain the oil 3 Mount the transfer case in a suitable fixture The fixture should be such that the case can be rotated so that either its front or its rear is facing upward A transfer case mounted in a typical fixture is shown in Figure 4 Figure 4 4 Remove the oil pump assembly and gasket 5 2 TRANSFER CASE COMPONENT REMOVAL For purposes of this manual a 180
11. fill and lower drain plugs and drain gear lubricant 2 Disconnect wire leading to indicator light switch and temperature sensor if used 3 Disconnect and tag shift cylinder air lines 4 Disconnect speedometer cable 5 Disconnect drivelines at flanges yokes 6 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 7 Disconnect transfer case mounting at the rubber shock insulators Since mounting designs vary consult the vehicle service manual 8 After making sure that all mounting 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 from falling off the jack Remove the transfer case from beneath the vehicle may be necessary to jack the truck up to allow room to remove the transfer case 4 4 INSTALLATION 1 Place the transfer case onto the transmission jack preferably lifting by means of the eye bolts 2 Position the transmission jack underneath the vehicle Some vehicles 625 0540 A may require that one side be jacked up in order to achieve sufficient clearance to place the transfer case between the frame rails Raise the transmission jack to properly locate the transfer case Connect transfer case mounting Since mounting
12. grease and 30W engine oil The mix should be thin enough to apply with a small brush 6 1 ASSEMBLY OF SUBASSEMBLIES In the following assembly procedures it is assumed that the various shaft assemblies were completely disassembled Skip any step that refers to a part that is already assembled Refer to section 4 2 in this manual for assembly precautions 6 2 ASSEMBLY OF THE INPUT SHAFT Figure 44 CAUTION WHEN PART IS ASSEMBLED WITH A PRESS FIT IT IS RECOMMENDED THAT THE PART BE HEATED PRIOR TO INSTALLATION IN A SUITABLE OVEN AT A TEMPERATURE NO GREATER THAN 300 Figure 43 3 Invert the input shaft and install the 1 Install a new oil seal and bearing cup in heated gear the spacer and the heated the input shaft carrier If removed bearing cone See Figure 45 install a new key in the input shaft 2 Heat and install the bearing cone assembly against the shoulder on the non threaded end of the input shaft See Figure 44 j j roa j A Figure 45 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 4 Place the carrier into position and slide the yoke or companion flange onto the shaft Install the yoke retaining locknut For convenience the nut may be torqued after the shaft assembly has been installed in the transfer case housing THIS CONCLUDES THE ASSEMBLY OF THE INPUT SHAFT 6 3
13. of the shaft should be checked prior to disassembly Install a dial indicator with a magnetic base as pictured in Figure 27 Lift upward on the carrier and note the amount of end float Figure 27 625 0540 A 2 Remove the yoke or companion flange retaining locknut with an impact wrench Slide the yoke or flange off the shaft 3 Place the shaft assembly in a press such that the face of the clutch gear is supported and the press arbor bears against the threaded end of the shaft oee Figure 28 Be sure that the outer diameter of the snap ring will clear the support Remove the carrier assembly the inner bearing cone assembly the bearing spacer ring and the clutch gear T Figure 28 4 Remove the oil seal from the carrier and discard Lift out the remaining bearing cone assembly Remove the bearing cups from the carrier only if they are to be replaced o Remove the snap ring from the shaft only if it or the shaft is to be replaced 5 8 4 REAR OUTPUT SHAFT DISASSEMBLY WITHOUT NEUTRAL Rear Output Shaft without Neutral Figure 29 Fabco Automotive Corporation Livermore Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A 1 Remove the yoke or companion flange locknut with an impact wrench Slide the yoke or flange off the shaft 2 Lift off the rear carrier assembly Remove the oil seal from
14. that the bearing cups are seated Note the indicated shaft end float on the dial indicator If the end float is not within specification 003 to 008 in the shim pack should be removed and replaced with a combination of shims which will provide the proper end float Be sure to recheck the end float after replacing with new shims 625 0540 A Figure 77 Install the oil pump using a gasket and 1 Position the transfer case with its front four bolts Torque to specifications See end nameplate facing upward Figure 76 2 If removed install the freeze plug into the shifter shaft bore of the front declutch housing Use non hardening Figure 76 sealer to prevent an oil leak Insert the front bearing cup into its bore and place the original shim pack on top of the bearing cup Ensure that the declutch in the next step compresses the bearing cup and shims into place See Figure 78 Figure 78 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A installed in the vehicle as in Figure 79 4 Position the front declutch housing on Install the ten cap screws and washers the transfer case such that the shifter to secure the carrier to the TC housing shaft bores are directly to the left of the Torque to specification lower shaft bore as viewed when the unit is installed in the vehicle See 9 Rotate transfer case over suc
15. the cone with a bearing separator and press the shaft through the cone See Figure 37 Figure 39 3 Remove four Cap Screws then the shift shaft cap See Figure 40 t Fig ure 40 Figure 37 10 Slide off clutch collar gear For steps 4 8 use Figure 41 for reference 5 8 6 SHIFT SHAFT DISASSEMBLY PTO AND FRONT OUTPUT 1 Remove the four plate screws holding the plate to the declutch housing Then Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A Front Output amp PTO Shift Shaft Figure 41 4 Remove the nut and washer 5 Take out the piston shift and stop 6 Remove compression spring 8 out the shift shaft 7 Uncase the shift cylinder adapter 9 Remove the fork shift together with the See Figure 42 clutch collar gear Fabco Automotive Corporation Livermore Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A 6 0 ASSEMBLY Make sure all parts are clean dry and lint free Any traces of storage wax or paper should be removed Leave bearings and cups in their wrapper until ready to use Do not handle parts any more than necessary Unless indicated otherwise part mating surfaces should be given a light coat of lubricant Lubriplate is acceptable A substitute may be used using a mixture of chassis
16. the carrier and discard Remove the bearing cup from the carrier only if it is to be replaced 1 4 Steps 3 4 and 5 are necessary only if one or more components remaining are to be replaced 3 Remove the front clutch gear retaining locknut with an impact wrench See Figure 30 Slide off the clutch gear 5 remove the remaining bearing cone assembly support under the cone with a bearing separator and press the shaft through the cone See Figure 32 Figure 30 4 Place the shaft assembly a press so that the gear is supported and the press arbor bears against the yoke end of the shaft See Figure 31 Remove the bearing cone assembly the spacer washer and the gear Remove the shaft key only if necessary Figure 32 Fabco Automotive Corporation Livermore Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 5 8 5 REAR OUTPUT SHAFT DISASSEMBLY WITH NEUTRAL 1 2 3 4 Figure 33 Remove the yoke or companion flange locknut on output side with an impact wrench Slide the yoke or flange off the shaft Remove the four cap screws securing the shift cylinder cap to the carrier Remove the cap and the nylon piston ring Discard the cap O ring Remove the piston retaining locknut and washer A wrench on the shift fork may be necessary to prevent the shaft from turning Lift the rear carrier assembly off the sha
17. ASSEMBLY OF THE INTERMEDIATE SHAFT Figure 46 1 If removed reinstall the keys into the key ways of the intermediate shaft 2 Heat the bearing cones and intermediate gear and press onto the intermediate shaft See Figure 47 Figure 47 The remainder of the intermediate shaft assembly must be done inside of the transfer case housing during the shaft installation procedure 625 0540 A CAUTION WHEN PART IS ASSEMBLED WITH A PRESS FIT IT IS RECOMMENDED THAT THE PART BE HEATED PRIOR TO INSTALLATION IN A SUITABLE OVEN AT A TEMPERATURE NO GREATER THAN 300 THIS CONCLUDES THE ASSEMBLY OF THE INTERMEDIATE SHAFT 6 4 ASSEMBLY OF THE FRONT OUTPUT AND PTO SHAFT Front Output Shaft Figure 48 1 Install the snap ring on the shaft 2 Place the shaft in an upright position with the fine threaded end up to protect the shaft threads and splines 3 Install the clutch collar gear onto the shaft such that the counter bore in the gear fits over the snap ring Ensure clutch collar gear is mated against snap ring before installing bearing cone 4 Heat the inner bearing cone and install it against clutch gear CAUTION WHEN PARI IS ASSEMBLED WITH A PRESS FIT IT IS RECOMMENDED THAT THE PART BE HEATED PRIOR TO INSTALLATION IN A SUITABLE OVEN AT A TEMPERATURE NO GREATER THAN 300F HEATED COMPONENTS MUST BE ALLOWED TO COOL BEFORE END FLOAT MEASUREMENTS ARE MADE Fabco Automotive Corporation
18. CE MANUAL 625 0540 A 5 6 FRONT OUTPUT SHAFT REMOVAL 6 Remove the air shift piston nut Exercise caution as the piston 15 spring loaded Remove the washer piston spring and the nylon stop ring EU 8 SN Say d gt B 7 Cut and remove the safety wire on the shift fork bolts and remove the bolts See Figure 16 Front Output Shaft T I g 11777777 EA 72 aun Figure 14 1 Position the transfer case with its front end facing upward 16 2 Remove the four cap screws securing the declutch housing cover plate 8 Remove the shift shaft It may be necessary to carefully pry open slightly 3 Remove the eight cap screws and the slot in the shift fork to free the shaft washers securing the carrier to the Lift out the shift collar and the shift fork declutch housing See Figure 17 4 Mark the position of the carrier to housing with chalk as it needs to be reassembled in the same position 5 Lift off the shaft assembly Discard the carrier gasket See Figure 15 Figure 17 9 Remove the six 12 point cap screws securing the declutch housing to the transfer case housing Retain shims together with the housing to facilitate reassembly Remove the bearing cup from the transfer case housing 10 Do not remove the freeze plug from the shift shaft bore in the declutch housi
19. E THIS CONCLUDES THE ASSEMBLY OF THE FRONT OUTPUT AND PTO SHAFT Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A 6 5 ASSEMBLY OF THE REAR OUTPUT CAUTION WHEN PART 15 SHAFT WITH NEUTRAL AND CARRIER ASSEMBLED WITH A PRESS FIT IT IS RECOMMENDED THAT THE PART BE HEATED PRIOR TO INSTALLATION IN A SUITABLE OVEN AT A TEMPERATURE NO GREATER THAN 300f HEATED COMPONENTS MUST BE ALLOWED TO COOL BEFORE END FLOAT MEASUREMENTS ARE MADE 2 Lubricate the thickest part of the shaft and the inner surface of the gear See Figures 54 and 55 Figure 52 1 Install the clutch collar gear onto the shaft See Figure 53 Figure 55 3 Then align and install the gear on the shaft See Figure 56 Figure 53 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 4 Figure 56 Install a thrust washer against the gear assembly followed by the small spacer Heat and install the bearing cone assembly on the shaft against the spacer Then place the clutch gear on top of the bearing assembly See Figure 57 Figure 57 6 Apply Loctite 290 or equal to the locknut and tighten to the required torque Invert shaft assembly and install the other bearing cone on top of the clutch collar Place the large spacer above the
20. Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 5 Install the inner bearing spacer ring The bearing cone spacer ring is a select fit part that is used to adjust the shaft end float If the end float checked prior to disassembly was within specification 003 to 008 in and no parts were replaced the original bearing Spacer ring should provide the correct end float on reassembly See Figure 49 Figure 49 6 Press the bearing cups into the carrier 7 Put the carrier onto the shaft and then the heated outer bearing cone See Figure 50 Figure 50 8 Do not install oil seal at this time Slide the yoke or companion flange onto the shaft Install and torque the locknut 625 0540 A 9 Mount a dial indicator on the shaft as shown in Figure 51 10 Lift the carrier up and note the indicated shaft end float on the dial indicator If the end float is not within specification 003 to 008 in it will be necessary to disassemble the shaft and repeat steps 5 8 using a bearing spacer ring of a different thickness 11 Remove the yoke or companion flange and install the oil seal CAUTION WHEN PARI IS ASSEMBLED WITH A PRESS FIT IT IS RECOMMENDED THAT THE PART BE HEATED PRIOR TO INSTALLATION IN A SUITABLE OVEN AT A TEMPERATURE NO GREATER THAN 300f HEATED COMPONENTS MUST BE ALLOWED TO COOL BEFORE END FLOAT MEASUREMENTS ARE MAD
21. SERVICE MANUAL 625 0540 A 180 TRANSFER CASE SERVICE MANUAL Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A Table of Contents MODEL TC 180 Transfer EXE EVER ERE Cenb as vena 150 NI 1 4 1 2 LUBRICATION voices scene U 2 0 Recommended 2 2 Edi ine pr PTS 2 9 Bramming Ne Ol crm 2 4 Renning the Olesna E ENE 2 5 ole sol gt 2 6 CLEEANING AND INSPECTION ede ecu iua cuoc Qux eed aou 3 0 E Drying and Corrosion 3 2 3 3 GENERALE INSTRUCTIONS 4 0 IM 4 1 nie tarsi 4 2 m
22. Shaft PTO The Fabco Model 180 is a family of Transfer Case and Split Shat Power Take offs with single speed three shaft constant mesh design The new Model 180 is the latest generation design replacing the Fabco Model 170 and 175 The Model 180 features increased oil capacity higher strength main housing increased torque capacity helical gearing ultra high temperature seals and gaskets revised declutching gearing and a proprietary Fabco lubrication pump yet retains same installation envelope of previous Fabco designs Ratings Nominal Torque Horsepower Input Speed Ratio Gear Type Shaft Sizes Input Front amp Rear Output Shaft Spacing Drop Shift Mechanism Bearings Lubrication System Lubricant Oil Capacity Nominal Weight Dry Housing 15 000 Lb Ft 18 000 Lb Ft Through Shaft 500 HP 3 000 RPM 1 1 Standard Contact Fabco for Optional Ratios Helical Case Hardened 2 50 Inches 10 Parallel Spline 16 25 Inches Integral Air Cylinders Tapered Roller Pressurized amp Splash SAE 50 75W90 GL4 MT 1 Synthetic Gear 12 0 Quarts 470 Lbs approx Precision Cast All ratings nominal Actual capacities determined based upon review of application by Fabco Engineering Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A 1 2 ASSEMBLY VIEWS The New Fabco Model 180 Transf
23. The filter element is of a spin on type A film of clean oil should be applied to the rubber gasket of the new filter element before installing Do not over tighten 2 5 REFILLING THE OIL If the transfer case has been removed from the vehicle for service it is the best to refill the oil after the unit has been reinstalled into the vehicle Clean and replace the drain plug and fill the transfer case with the appropriate oil with the vehicle on level ground Fill the transfer case to the level of the sight glass 2 6 OPERATING TEMPERATURE he operating temperature of the transfer case should not exceed 250 1200 Extensive operation at temperatures exceeding 2504 will result in rapid brake down of the oil and may shorten the transfer case life reduction of operating speeds is not acceptable then the case may have to be equipped with external oil cooler to maintain the operating temperature below 250F The following conditions may contribute to excessive oil temperatures 1 A vehicle which is used in tropical or desert conditions 2 A vehicle where extended body work or an accumulation of dirt and plant material may shield the case from air ventilation and circulation 3 A vehicle that is operated for extended distances at high speed with the main transmission in overdrive Fabco Automotive Corporation Livermore Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL
24. embly of the Front Output and PTO 4442 6 4 Assembly of the Rear Output Shaft and 6 5 General 6 6 Intermediate Ras 6 6 1 Rear Outout shatt eo a Rai i 6 6 2 Front Output amp 6 6 3 5 6 6 4 Fabco Automotive Corporation Livermore Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A TORQUE SCIFICA TIONS D 7 0 SEAL INSTALLATION 5 0 FOOLS em 9 0 ILLUSTRATED PARTS AND 115 PARTS MANUAL Fabco Automotive Corporation Livermore Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A 1 0 MODEL TC 180 Transfer Case 1 1 INTRODUCTION AUTOMOTIVE CORPORATION FABCO Model 180 Transfer Case amp Split
25. er Case amp Split Shaft PTO New high strength precision housing Rousing has thicker section enhanced materia properties and revised geometry a BEEN to give maximum durability Available with large range of Lifting bosses hydraulic pump FTO Sn SAE pam support bosses and fill hole configurations on top of the housing New coarse pitch high strength forged helical gearing gives increased torque amp horsepower capacity while retaining quiet performance Retains same mounting pattem and drive shaft spacing as the popular Fabco Model 170 amp 175 making customer integration easy Fabco proprietary oii pump for imaroved Service performance Military in theatre proven design New ultra high temperature oil seais gaskets and o rings Improved lubrication distribution at critical shaft beanngs Compatible with commercially available el sump drive yokes amp flanges Larger oil sump for Improved lubrication Revised declutch gear tooth profile throughout for optimized shifting performance Figure 1 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A aes NZ ED k Am F IL 1 OC D 7 pan ND 7 CIS 2 18i antl ARIES eR ZA Em FRONT pct
26. ermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A 25 FT LBS ae CD eM Saar um ag Sey udi 7 45 FT LBS 8 FT LBS ADDITIONAL TORQUE SPECIFICATIONS OIL FILL DU FT LBS OIL LEVEL SIGH PLUG 99 BTISBDBS TEMPERATURE SENSOR PLUG 25 FT LBS OIL FILTER BRACKET 15 FT LBS ALL TORQUE FT LBS VALUES ARE FOR DRY UNLUBRICATED THREADS AND SHOULD BE WITHIN 10 OF THE VALUES SHOWN Figure 102 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL CAUTION CARE MUST BE EXERCISED TO AVOID DRIVE YOKE DAMAGE 4 625 0540 A 8 0 SEAL INSTALLATION INSTRUCTIONS Drop driveline to access the yoke or flange retaining nut Remove the retaining nut from the shaft Input sectional view shown in Figure 103 EAL LIPS HAFT SPLINES 72 4 RIVE YOKE SEAL JOURNAL RIVE YOKE Figure 103 Pull the yoke straight off the shaft Inspect yoke to verify it is in good condition If excessive wear is noted the yoke should be replaced If any burrs are found on the seal journal or beveled corner they should be removed if the yoke 15 to be reinstalled Pull the old seal from the housing carrier For the input location remove three screws and washers prior
27. ft and slide the shift fork from the clutch gear Remove the oil seal from the carrier and discard Remove the bearing cup from the carrier only if it is to be replaced 5 Remove the piston and the nylon stop ring from the carrier Discard all O rings 6 To facilitate reassembly the gear end float on the shaft should be checked to further disassembly Install a dial indicator with a magnetic base as pictured in Figure 34 Lift upward on 625 0540 A the gear and note the amount of end float n uM Figure 34 7 Remove the clutch gear retaining locknut on the other side of the shaft with an impact wrench and slide off the clutch gear See Figure 35 35 Steps 8 9 10 are necessary only if one or more components remaining are to be replaced 8 Place the shaft assembly in a press so that the gear is supported and press arbor bears against the yoke end of the shaft to remove the bearing cone Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A assembly the spacer washer and the remove the plate and gasket See gear See Figure 36 Figure 38 a Figure 38 2 Remove bolt safety wire and bolts See Figure 39 Figure 36 9 remove the remaining bearing cone assembly slide the clutch collar towards the thrust washer and support under
28. h that its Figure 79 shafts are horizontal Mount a dial indicator on the shaft as shown in Figure 81 Pry the rear output shaft up and down several times to be sure that the front bearing cup is seated Note the indicated shaft end float on the dial ae indicator If the end float is not within m MS ER ME specification 003 to 008 in the shim eS j pack should be removed and replaced with a combination of shims which will provide the specified end float Be sure to recheck the end float after replacing with new shims FRONT DECLUTCH HOUSING 2 79 5 Install the six 12 point screws and torque to specification 6 Rotate the TC over so that its rear end is facing upward 7 Position a new gasket on the TC housing and lower the rear output shaft assembly into place See Figure 80 Figure 81 6 6 3 FRONT OUTPUT AND PTO SHAFT INSTALLATION Front Output Shaft Figure 82 Figure 80 1 In order to install the Front output shaft it 8 The word TOP on the rear carrier must is necessary to reinstall the shift shaft be toward the top of the transfer case as assembly Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 2 Position the transfer case with its front end name plate upward The front declutch housing should already be installed See Figure 79 3 Slide the shift fork
29. he transfer case over so that Its front end is facing upward 6 Make sure that the rear bearing cup is still in place Position a new gasket on the transfer case housing and lower the shaft assembly into place See Figure 97 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 8 Figure 97 7 Align and install the carrier The word TOP on the carrier must be toward the top of the transfer case as installed in the vehicle Torque the ten cap screws and washers to specification See 9 Figure 98 10 98 625 0540 Rotate transfer case such that shafts are horizontal Mount a dial indicator on the shaft as shown in Figure 99 Figure 99 Pry the gear up and down several times to be sure that the bearing cups are seated Note the indicated shaft end float on the dial indicator If the end float is not within specification 003 to 008 in the shim pack should be removed and replaced with a combination of shims which will provide the proper end float Be sure to recheck the end float after replacing with new shims To install the PTO Shaft turn the TC housing so its rear is facing up and follow steps in section 6 6 3 starting with step 3 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com
30. ico P 4 3 ARES 4 4 Y eere 5 0 Gencral Disassembly TEE 5 1 Transfer Case Component Removal 5 2 sili _______ we 5 3 MOUSA REMOVA _____ t ed 5 4 Hear Output Shalt Removal assessed e uo RO 5 5 Front Output Shat Removal Heeb aa Send Ea 5 6 lhiterimediate Shalt REMOVA Subasserbli6S sso cse bis 5 8 Iniparshar DISassermbly csse din ade stet a 5 8 1 Intermediate Shaft 2 5 8 2 Front Output and PTO Shaft Disassemibly cnie at rhet ot 5 8 3 Rear Output Shalt a 5 8 4 Shift Shaft 5 8 5 ASSEMBLY TRETEN 6 0 Assembly DUO 6 1 Assembly Or 99 6 2 Assembly Of the Intermediate nae alee eee ee eal che eked 6 3 Ass
31. is facing upward 10 Remove the six cap screws and washers securing the rear cap to the transfer case Remove the cap shim pack and rear bearing cup Keep the shims together with the cap to facilitate reassembly 7 Figure 19 uu This concludes the general disassembly 4 Position the transfer case with its front end facing upward 5 Remove the six cap screws and washers securing the front intermediate Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 5 8 SUBASSEMBLIES During a normal overhaul it is neither necessary nor desirable to completely disassemble the shaft assemblies The bearing cone assemblies and the drive train gears are installed with a press fit to the shaft and their unnecessary removal only increases the likelinood of damage The same applies to the bearing cups installed in the carriers Parts should be cleaned with emulsion cleaners or petroleum solvents To avoid damage alkaline solutions should not be used 5 8 1 INPUT SHAFT DISASSEMBLY Figure 21 1 Remove the input yoke or companion flange retaining locknut with an impact wrench Slide off the clutch gear if provided on the rear side Slide the input yoke or flange off the shaft on the input side 2 Lift off the input carrier assembly Remove the oil seal from the carrier and discard Remove the bearing cup from the carrier only if it is t
32. ith Loctite 601 or equivalent on their outer diameter prior to being installed in their bores The sealing lips should be coated with Lubriplate or the equivalent to provide initial lubrication All external cap screw should have there threads coated with loctite threaded fasteners should be tightened to the torque specified in the torque specification section Any sharp edges on the seal diameter of the universal joint yoke or companion flanges should be removed with emery cloth and should be coated with Lubriplate or the equivalent on the seal operating area prior to installation In many of the procedures when a part is assembled with a press fit it Is recommended that the part be heated prior to installation The part should be placed in an oven and heated to no more that 300 Excessive heat my change the metallurgical properties of the part Heated components should be allowed to cool to room temperature before end float measurements are made Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL CAUTION ALTHOUGH FABCO DOES NOT RECOMMEND ITS USE IN TRANSFER CASES FORMED IN PLACE GASKET IS USED FOR REPAIRS EXTREME CAUTION MUST BE EXERCISED PREVENT THE COMPOUND FROM ENTERING BEARINGS OIL GALLERIES AND PASSAGES TAPPED HOLES ALL BEADS MUST BE KEPT SMALLER THAN 1 8 INCH DIAMTER 4 3 REMOVAL 1 Remove
33. ke seal journal and drive yoke bevel with transfer case fluid Start the drive yoke on the shaft ensuring the splines properly engaged and slide freely Push the drive yoke onto the shaft until it seats Check dust lip to ensuring that it is not folded under and is facing out If dust lip is folded under pull out drive yoke 2 to 1 inch rotate and push in reseating drive yoke Repeat until dust lip is correctly installed 13 14 15 625 0540 A For input location install a new unused retaining locknut Torque the nut to 800 For Front and Rear output locations install a new unused retaining locknut Torque the nut to 800 Ib ft Rotate the drive yoke by hand to check for binding or interference Recheck oil level and fill as necessary Fabco Automotive Corporation Livermore Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A 9 0 TOOLS Details of tooling to facilitate the servicing of the Fabco TC 180 Transfer Case Service tools may be manufactured to these drawings or Automotive may be contacted for pricing and availability The manufacture of these tools should be carried out by professional machinists and certified welders following typical and good workmanship procedures and safe practices E EUETERLAL HEAT MHH WHESE USED OIL SEAL 732 0467 SEAL DRIVER TC 180 Wire OF PAAT ola z
34. ment of such parts can prevent costly downtime at a future date Al bearing surfaces including roller bearings cups and cones should be examined for pitting wear or overheating Gears may also show pits as well as scoring and broken teeth Shafts may be nicked or marked or have damage threads Parts which show any signs of damage should be repaired replaced Inspect the oil pump If any damage is noted the pump 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 partial engagement wear pattern NOTES Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A 4 0 GENERAL INSTRUCTIONS 4 1 SAFETY The servicing maintenance components from any automotive vehicle present possible hazards every endeavor should be made to minimize the risk taken to successfully complete the task For your protection we offer these warnings and suggestions 1 When working on around or under the vehicle the parking brake should be securely applied and all wheels should be blocked to prevent wheel movement Do not rely on the vehicle being in gear with a dead engine to prevent movement All work should be performed on a flat level surface free of loose material 2 When working under a vehicle it should be raised
35. ng unless necessary Figure 15 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A 5 7 INTERMEDIATE SHAFT REMOVAL cap Remove the cap and discard the gasket 6 Remove the front bearing cup by pulling upwards on the intermediate shaft assembly intermediate 4 Shaft ae We 7 The gear and the rear bearing cone both Eu GN Set have a press fit to the intermediate shaft Therefore a puller will be necessary to remove the shaft if damage is to be avoided A sketch depicting a suitable fabricated puller is illustrated in Figure 20 STEEL TUBING 6 0 O D x 1 4 WALL x 4 0 LONG HEX NUT AND WASHER Figure 18 On Models not equipped with a lubrication pump begin the procedure at Step 4 1 Position the transfer case with its rear end facing upward STEEL PLATE he K DRILLED HOLE TO CLEAR ROD 2 Remove the four cap Screws and 58 11 OR 34 16 washers securing the oil pump and T LONG remove it Discard the gasket Figure 20 3 Remove six cap screws securing the 8 To prevent damage do not allow the intermediate shaft cap Remove cap bearing cone assembly or the gear to oee Figure 19 drop inside the case as the shaft is being pulled out Remove the shaft gear spacer and bearing cone assembly 9 Rotate the transfer case over so that its rear end
36. ng onto the shift cylinder cap See Figure 64 Felt Weer O Ring oh Washer O Ring Shifter Shaft Nylon Washer Shift Piston Nylon Washer Shift Cylider Cap Figure 64 15 Screw in the shift cylinder cap using four screws again using Loctite 272 or equal See Figure 65 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 625 0540 A 19 Screw in a fitting onto the shift cylinder cap See Figure 68 Figure 65 16 Slip the yoke or companion flange onto the shaft and secure it with locknut 17 Insert the indicator switch actuation pin Figure 68 into place The rounded end of the pin must face inward See Figure 66 THIS CONCLUDES THE ASSEMBLY OF THE REAR OUTPUT SHAFT WITH NEUTRAL 6 6 GENERAL ASSEMBLY 6 6 1 INTERMEDIATE SHAFT INSTALLATION Figure 66 Figure 69 18 Install the switch using a new copper washer Torque to specification See Figure 67 1 Position the transfer case with its front end nameplate facing upward 2 Heat the intermediate shaft gear and lower it into the transfer case housing through the lower or upper shaft bore Position the gear against the rear of the housing in line with the intermediate shaft bores See Figure 70 Figure 67 Fabco Automotive Corporation Livermore Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com
37. o be replaced It is not necessary to disassemble the shaft assembly any further unless one or more of the components remaining are to be replaced 3 Place the shaft assembly in a press so that the rear of the gear is supported and the press arbor bears against the threaded end of the shaft See Figure 22 Remove the front bearing cone assembly the spacer washer and the gear 625 0540 A Figure 22 4 Toremove the rear bearing cone assembly support under the cone with a bearing separator and press the shaft through the cone See Figure 23 Remove the shaft key only if necessary Figure 23 5 8 2 INTERMEDIATE SHAFT DISASSEMBLY Figure 24 It is not necessary to disassemble the intermediate shaft assembly unless a component is to be replaced 1 remove the bearing cone assembly support under the cone with a bearing separator and press to shaft through the cone See Figure 25 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL Figure 25 2 Remove the shaft key only if necessary 5 8 3 FRONT OUTPUT AND PTO SHAFT DISASSEMBLY Front Output Shaft PTO Output Shaft f mm ii T A 1 7 1 Er AE WX 3 AES 1 v 2 w Figure 26 1 To facilitate reassembly the end float
38. onto the clutch collar and place the two parts as a unit into the declutch housing See Figure 83 EL SIDE Figure 83 4 The clutch collar and fork must be installed in the right direction so that the shift fork bolts can be installed on the machined side See Figure 84 Figure 84 5 Insert the shift shaft into position Rotate the shift shaft so that the slots lineup with the bolt holes in the shift fork Install the 2 shift fork bolts and torque to specification Install the lock wire 625 0540 A between the two bolt heads See Figure 85 Figure 85 6 Install a new piston to shaft O ring over the threaded portion of the shaft Slide the spring over the shaft Place the nylon stop ring over the shaft and spring Install a new piston O ring in the outer groove in the piston Soak the air shift piston felt strip in gear oil and install it in the inner groove See Figure 86 Pas y is gt Felt Wiper Shitt Shatt Spring Shift Cylider Adapter O Ring Lock Nut Washer Figure 86 7 Position the piston on the shifter shaft The end of the piston with the counterbore should be facing outward Push the piston down to compress the spring and install the shifter shaft washer and locknut Torque the nut to specification See Figure 87 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL Figure 87
39. tervals Highway Service 1 000 Miles Off Highway Service 40 Hours With every oil change the shift cylinder air lines and valves should be inspected for leaks and possible malfunctioning Low pressure conditions can cause partial clutch engagement which may result in premature wear or damage 2 3 OIL CHANGE The transfer case lubricant should be changed on all new transfer cases after the first 3 000 to 5 000 miles on highway or the first 40 hours off highway thereafter oil changes should be done at the following intervals On Highway Service 10 000 15 000 Miles Off Highway Service 500 700 Hours The recommended oil change and inspection periods are based on 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 units specific operating conditions With this data the oil change and inspection periods can be better determined 2 4 DRAINING THE OIL Draining is best accomplished after the vehicle has been operated briefly allowing the 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 The lube oil filter should be replaced whenever the oil is changed
40. to seal removal Clean the seal bore in the housing carrier where the old seal had been located Inspect the new seal to verify that the lio material is intact and in good condition free of any nicks or marks Also check the outside diameter of the new seal for any dents or burrs If any are found the seal should not be installed Place seal on seal driver tool as shown in Figure 104 below ensuring the spring side is facing away from the seal driver tool For top input and rear output locations use seal 732 0467 SPRING and seal driver 866 0888 For Front output location use seal 732 0466 seal driver 866 0861 i Lil FA tl 17 FA Cr CL a DUST LIF SIDE SEAL DRIVER Figure 104 Place seal driver on shaft For input location drive seal into bore with old nut 688 0738 For Front and Rear output locations drive seal into bore with old retaining nut Seal driver will stop when seal is fully seated against shoulder on housing carrier bore Input installation shown in Figure 105 Figure 105 For input location remove old nut and seal driver Re install screws washers For Front and Rear output locations remove old nut and seal driver Fabco Automotive Corporation Livermore Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL 10 11 12 Lubricate the shaft splines seal lips drive yo
41. with PTO contains five shaft assemblies Input Intermediate Front Output Rear Output and PTO shaft assembly Be sure to use the correct procedure for each shaft assembly In some procedures a similar procedure for a different shaft is called out 1 Remove oil strainer See Figure 5 Figure 5 2 Remove the four hoses Remove oll filter from the oil filter bracket See Figure 6 Figure 6 3 Remove the four bolts securing the filter bracket then the filter bracket itself See Figure 7 Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com SERVICE MANUAL Figure 7 4 Remove the three indictor light switches and washers located on the front side of the transfer case attached to the housing on the FRONT OUPUT SHAFT the transfer case s back side on the declutch housing and the rear output carrier See Figure 8 Figure 8 5 Remove the three switch actuating pins with a pencil magnet See Figure 9 625 0540 A Figure 9 6 See Section 5 8 5 for removal of the air shift cylinders from the declutch housings 5 3 PTO Shaft removal Figure 10 To remove the PTO shaft assembly and declutch housing refer to section 5 6 Front Output Shaft Removal for similar procedure Fabco Automotive Corporation Livermore CA Ph 925 454 9500 1 800 967 8838 Fax 925 454 9501 www fabcoautomotive com
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