C.Shift Shaft DisassemblyAir Shift Cases1.Remove bolts and lockwashers from cover plate.Tap cover plate to loosen and remove.Fig. 32.Unscrew indicator light switch from the housing andremove spacer washers (Note amount of spacersremoved). Remove plunger from inside housingusing a magnet.3.Cut the lockwires from the shift fork set screws oneach shift fork. Remove the set screws from eachshift fork.4.Remove four bolts from the shift cylinder cap andremove cap from shift cylinder. Discard o-ring fromcylinder cap, if replacement is necessary.5.Remove shift cylinder tube from the shift cylinderadapter tube located in the housing, exposing piston(See fig. 4).Fig. 46.Withdraw shift piston and shift shaft housing. As theshift shaft is withdrawn from the housing, removeeach shift fork from the shaft.7.Remove shift shaft spring and plastic stop ring fromthe shift shaft or from the shift cylinder adapter tubelocated in the housing.8.Disassemble shift piston from the shift shaft (ifnecessary) and discard o-ring and felt wiper, ifreplacement is necessary.9.Remove shift cylinder adapter tube from housing.Discard o-rings from the adapter, if replacement isnecessary.10. Remove shift forks from inside of housing.Manual Shift Cases1.Remove bolts and lockwashers from cover plate.Tap cover plate to loosen and remove (See fig. 3).2.Unscrew indicator light switch from housing andremove spacer washers (Note the amount ofspacers removed). Remove plunger from insidehousing using a magnet.3.Cut the lockwires from the shift fork set screws oneach shift fork. Remove the set screws from eachshift fork.4.Remove each detent set screw from housing.Discard set screws and replace for reassembly.Remove each detent spring and each detent ball.Detent balls are removed by using a magnet.5.Remove four bolts from each shift shaft seal carrierand remove seal carriers from housing.6.Withdraw each shift shaft from housing. As the shiftshaft is withdrawn from the housing, remove eachshift fork from the shaft.7.Remove seal from each seal carrier, if replacementis necessary.8.Remove shift forks from inside of housing (Labelingthe shift forks according to their position in thetransfer case will aid in reassembly).-12-
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