C.
Shift Shaft Disassembly
Air Shift Cases
1.
Remove bolts and lockwashers from cover plate.
Tap cover plate to loosen and remove.
Fig. 3
2.
Unscrew indicator light switch from the housing and
remove spacer washers (Note amount of spacers
removed). Remove plunger from inside housing
using a magnet.
3.
Cut the lockwires from the shift fork set screws on
each shift fork. Remove the set screws from each
shift fork.
4.
Remove four bolts from the shift cylinder cap and
remove cap from shift cylinder. Discard o-ring from
cylinder cap, if replacement is necessary.
5.
Remove shift cylinder tube from the shift cylinder
adapter tube located in the housing, exposing piston
(See fig. 4).
Fig. 4
6.
Withdraw shift piston and shift shaft housing. As the
shift shaft is withdrawn from the housing, remove
each shift fork from the shaft.
7.
Remove shift shaft spring and plastic stop ring from
the shift shaft or from the shift cylinder adapter tube
located in the housing.
8.
Disassemble shift piston from the shift shaft (if
necessary) and discard o-ring and felt wiper, if
replacement is necessary.
9.
Remove shift cylinder adapter tube from housing.
Discard o-rings from the adapter, if replacement is
necessary.
10. Remove shift forks from inside of housing.
Manual Shift Cases
1.
Remove bolts and lockwashers from cover plate.
Tap cover plate to loosen and remove (See fig. 3).
2.
Unscrew indicator light switch from housing and
remove spacer washers (Note the amount of
spacers removed). Remove plunger from inside
housing using a magnet.
3.
Cut the lockwires from the shift fork set screws on
each shift fork. Remove the set screws from each
shift 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 carrier
and remove seal carriers from housing.
6.
Withdraw each shift shaft from housing. As the shift
shaft is withdrawn from the housing, remove each
shift fork from the shaft.
7.
Remove seal from each seal carrier, if replacement
is necessary.
8.
Remove shift forks from inside of housing (Labeling
the shift forks according to their position in the
transfer case will aid in reassembly).
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