I. Manual Shifter Shaft Installation
Refer to Page PM9 and Page PM11
There are three (each a different length) shift forks
used in the TC-35 transfer case. Their lengths are
indicated and their positions explained in the
The shift shafts and shift forks must be installed after
the drive shafts and gears are in place.
Insert the H-N-U shift shaft (Item 46 with 5 grooves)
into the shift shaft hole next to the input shaft. Once
the end of the shift shaft is visible through the cover
opening, position the direct drive clutch shift fork
(Item 34, which is 5t/s over-all in length) into the
groove in the clutch on the input shaft with the long
hub portion of the shift fork toward the shift shaft
(front of the case). Slide the shift shaft through the
shift fork just enough to clear the underdrive shift
fork (Item 35, which is 7 5/8 long) that is to be
installed at this time with hub end facing the rear of
the case and with the forked end in the groove in the
clutch on the intermediate shaft. Slide the shifter
shaft through this fork and into the hole on the back
of the case.
Align the underdrive shift fork (Item 35) retaining
screw hole with the rear-most groove in the shift
shaft. Install a shift fork set screw (Item 17) into this
fork, position the flat face of the eye end of the shift
shaft parallel to a line through the input and rear
output shaft centerlines. This will put flat side in a
vertical plane on the installed case. Tighten the set
screw to specifications.
Slide the direct drive fork (Item 34) and clutch to
position the forks set screw hole over the next shifter
shaft groove, install the set screw (Item 17). As the
set screw is tightened, hold the two shift forks (both
either clockwise or counter clockwise) to insure
maintenance of fork-to-clutch clearance. Tighten
both set screws to specification and safety wire.
Insert the front drive shift shaft (Item 29, or-three-
groove shaft) into the hole closest to the, front drive
Slip the shift travel limiting tube (Item 33) onto the
end of the front drive shift shaft as it emerges on the
inside of the case.
Place the forks of the front drive shift fork (Item 16,
which is 6 3/4" overall in length) in the groove in the
front drive clutch.
Align hub end of shift fork with the front drive shift
shaft which should be inserted through the fork and
into the hole in the back of the case housing inner
10. Rotate shaft so flat face of the eye end of the shaft is
parallel to a line connecting the centerline of the
input shaft with the rear output shaft centerline and
with the flat or longitudinally grooved portion (on the
rear end of the shift shaft) away from the front drive
indicator switch hole. Failure to do this may result in
improper switch operation.
11. Align the shift shaft rear most circumferential groove
under the shift fork set screw hole. Install set screw
(Item 17), tighten to specifications and lockwire.
12. Insert seal (Item 27) in cylinder caps (Item 28) with
lip facing down. Install cylinder caps on front of case
(over shift shaft ends) with the seal to the outside.
Fasten to case housing with the appropriate bolts
13. 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
14. Cover exposed end of shifter shafts with the gaskets
(Item 23) and covers (Item 24) provided. Secure
15. Insert each detent ball and detent spring into proper
bore in top of housing. Install each detent set screw
and tighten until it takes a force of 25-40 lbs. to push
the shift shaft out of detent.