I.  Manual Shifter Shaft Installation Refer to Page PM9 and Page PM11 1. 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 following paragraphs. 2. The shift shafts and shift forks must be installed after the drive shafts and gears are in place. 3. 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. 4. 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. 5. Slide  the  direct  drive  fork  (Item  34)  and  clutch  to position the fork’s 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. 6. Insert  the  front  drive  shift  shaft  (Item  29,  or-three- groove shaft) into the hole closest to the, front drive output. 7. 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. 8. 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. 9. 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 wall. 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 (Item 26). 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 operate properly. 14.  Cover exposed end of shifter shafts with the gaskets (Item  23)  and  covers  (Item  24)  provided.    Secure with 4 bolts (Item 25) each tightened to specifications. 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. -25-