5.Install the 7 5/8" overall length underdrive shift fork(Item 35); it should fit into the groove of theunderdrive shift clutch (on the intermediate shaft) thelong hub section should be facing the rear of thecase. Insert the two-groove shift shaft (Item 36) intothe adaptor tube (Item 15) at the rear of the casehousing (see 1 of this section). Slide end of shiftshaft into underdrive shift fork (Item 35). Put 5 7/8"overall length shift fork (direct drive shift fork-Item34) long hub toward front of the case, into the casewith the forks in the groove in the direct drive clutchon the input shaft. Push shift shaft through this fork(See Fig. 35) and into the hole in the front wall of thecase housing. Push on the end of the piston andcompress the spring until the piston butts against thenylon stop ring and the adaptor. This will allow theset screw in the underdrive shift fork (Item 35) to betightened into the proper groove on the shift shaft.Rotate both shift forks in either direction but in thesame direction and, with the second fork in theproper place longitudinally, tighten set screws tospecified torque and install the lockwire.Fig. 356.Place the forks of the front drive shift fork (63/4" longoverall Item 16) in the groove in the front driveclutch. Insert the front drive shift shaft (shaft with asingle groove for the single shift fork Item 12), spring(Item 14) and nylon stop ring (Item 13) into the shiftcylinder adapter previously installed in the front ofthe case housing. Pass the shaft (Item 12) throughthe shift fork and into the hole at the back of thecase. Rotate the shaft to position the longitudinalgroove away from the indicator light switch hole.Push on the piston enough to put the groove in theshaft under the set screw in the shift fork. Tightenthe set screw to specifications and lockwire.7.Soak the air shift piston felt washers (Item 10)with gear oil and install in the shallow groove ofthe piston (shift shaft side of piston). Install theshift piston o-ring (Item 8) in the deeper grooveon the pistons (Item 9). Oil the rings.8.The shift cylinder tubes are of differing lengths. Theshortest tube (Item 4 which is 3-1/16" long) shouldbe slipped over the front axle shift piston on the frontof the case. The longest shift cylinder tube (Item 37which is 3-13/16" long) should be fitted over the high-underdrive shift piston on the rear of the case.9.If the transfer case is equipped with a PTO unit, thecase must have a neutral position. Neutral isobtained through the use of a "piggy-back" cylindermounted on the high-neutral cylinder (see PagePM7). This "piggy-back" cylinder, when actuated byproperly connected air valves, provides this neutralposition. The "piggy-back" cylinder consists of anadaptor (Item 41) into the grooves of which areinstalled oiled o-rings the adaptor may be put eitherend first (it is symmetrical) into the end of the high-neutral shift cylinder tube (See Fig. 36). The air inletconnection should point in the same direction aswhen removed. The "piggy-back" shift shaft pistonassembly (with nylon stop ring over the end of theshaft) 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 capson cylinder tube open ends. Fasten to case housingwith the appropriate bolts (Item 5 or 38) or studs(Item 44) and nuts (Item 45).11. Install plunger (Item 22) into the front drive switchhole with the rounded end toward the shaft. Installthe shift indicator switch (Item 20) with one copperwasher (Item 21). Test switch operation with acircuit tester while shifting into and out of front drive.Add washers as necessary to make the switchoperate properly.12. Cover exposed end of shifter shafts with the gaskets(Item 23) and covers (Item 24) provided. Securewith 4 bolts (Item 25) each tightened tospecifications.Fig. 36-24-
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