11. Check fit between the split ring, underdrive pinion
gear and the input shaft split ring groove.
12. Temporarily fasten the input shaft rear cover (Item
25) or the PTO assembly (See Section J for
instructions on proper assembly of the PTO unit) in
place with the mounting bolts torqued to 25 lb. in.
13. Use feeler gauges to measure the distance between
the input shaft rear cap (or PTO assembly) and the
case housing (See Fig. 33). Add .005" to this
dimension and make a shim pack (Item 16) equal to
the dimension thus calculated, or at a maximum,
.005" larger than the calculated dimension.
14. Remove cap (or PTO), position shims, install cap (or
PTO) attaching with screws that have been coated
on the threads with Permatex. When installing the
PTO unit, lightly coat under the heads of the two long
H. Air Shifter Shaft Installation
Refer to Page PM7 and Page PM10
Install two o-rings (Item 3) into the grooves on the
outside of the shift cylinder adapter tubes (Item 15).
Coat adapters with gear lubricant or Lubriplate and
install in the counterbored shift shaft holes, on the
front of the case housing for the front drive shift and
on the rear of the case housing for the high-
underdrive or high neutral-underdrive-shift.
Place a small (piston-to-shift-shaft sealing) o-ring
(Item 11) over the threaded end of each shift shaft.
The shallow counterbore in the piston (Item 9)
should be toward the shoulder on the shift shaft; the
deep counterbore provides room for the retaining
nut. Install the piston retaining washers (Item 7) in
the deep counterbore of the piston over the end of
the shift shaft. Install piston retaining nut (Item 6 or
39). The nut used on the two groove shift shaft will
be a special oversized nut (Item 39) if the transfer
case is equipped with a PTO unit. Tighten nut to
specification and tighten the nut locking set screw
(Item 40) into the end of the special nut (Item 39-if
case has a PTO unit). See Fig. 34.
Install a spring on the two main or longer shift shafts
(Item 12 and 36) against the piston. Place a nylon
stop ring (Item 13) over the end of each shift shaft.
Start the set screws into the shift forks. Put them in
as far as possible and still allow the shift shaft to
slide through the hole.