Install the 7 5/8" overall length underdrive shift fork
(Item 35); it should fit into the groove of the
underdrive shift clutch (on the intermediate shaft) the
long hub section should be facing the rear of the
case. Insert the two-groove shift shaft (Item 36) into
the adaptor tube (Item 15) at the rear of the case
housing (see 1 of this section). Slide end of shift
shaft into underdrive shift fork (Item 35). Put 5 7/8"
overall length shift fork (direct drive shift fork-Item
34) long hub toward front of the case, into the case
with the forks in the groove in the direct drive clutch
on the input shaft. Push shift shaft through this fork
(See Fig. 35) and into the hole in the front wall of the
case housing. Push on the end of the piston and
compress the spring until the piston butts against the
nylon stop ring and the adaptor. This will allow the
set screw in the underdrive shift fork (Item 35) to be
tightened into the proper groove on the shift shaft.
Rotate both shift forks in either direction but in the
same direction and, with the second fork in the
proper place longitudinally, tighten set screws to
specified torque and install the lockwire.
Place the forks of the front drive shift fork (63/4" long
overall Item 16) in the groove in the front drive
clutch. Insert the front drive shift shaft (shaft with a
single groove for the single shift fork Item 12), spring
(Item 14) and nylon stop ring (Item 13) into the shift
cylinder adapter previously installed in the front of
the case housing. Pass the shaft (Item 12) through
the shift fork and into the hole at the back of the
case. Rotate the shaft to position the longitudinal
groove away from the indicator light switch hole.
Push on the piston enough to put the groove in the
shaft under the set screw in the shift fork. Tighten
the set screw to specifications and lockwire.
Soak the air shift piston felt washers (Item 10)
with gear oil and install in the shallow groove of
the piston (shift shaft side of piston). Install the
shift piston o-ring (Item 8) in the deeper groove
on the pistons (Item 9). Oil the rings.
The shift cylinder tubes are of differing lengths. The
shortest tube (Item 4 which is 3-1/16" long) should
be slipped over the front axle shift piston on the front
of the case. The longest shift cylinder tube (Item 37
which is 3-13/16" long) should be fitted over the high-
underdrive shift piston on the rear of the case.
If the transfer case is equipped with a PTO unit, the
case must have a neutral position. Neutral is
obtained through the use of a "piggy-back" cylinder
mounted on the high-neutral cylinder (see Page
PM7). This "piggy-back" cylinder, when actuated by
properly connected air valves, provides this neutral
position. The "piggy-back" cylinder consists of an
adaptor (Item 41) into the grooves of which are
installed oiled o-rings the adaptor may be put either
end first (it is symmetrical) into the end of the high-
neutral shift cylinder tube (See Fig. 36). The air inlet
connection should point in the same direction as
when removed. The "piggy-back" shift shaft piston
assembly (with nylon stop ring over the end of the
shaft) should now be inserted into the "piggy-back"
adaptor. Slip the "piggy-back" shift cylinder tube
(Item 43 which is 31/e" long) over this piston.
10. Insert o-rings in cylinder caps, install cylinder caps
on cylinder tube open ends. Fasten to case housing
with the appropriate bolts (Item 5 or 38) or studs
(Item 44) and nuts (Item 45).
11. Install plunger (Item 22) into the front drive switch
hole with the rounded end toward the shaft. Install
the shift indicator switch (Item 20) with one copper
washer (Item 21). Test switch operation with a
circuit tester while shifting into and out of front drive.
Add washers as necessary to make the switch
12. Cover exposed end of shifter shafts with the gaskets
(Item 23) and covers (Item 24) provided. Secure