TC 170 & TC 170 PD TRANSFER CASE

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1 Automotive Corporation TC 170 & TC 170 PD TRANSFER CASE PARTS MANUAL Fabco Automotive Corporation, Livermore, CA Ph:(925) Fax:(925) (800)

2 VII. PARTS MANUAL TABLE OF CONTENTS Fig. P Fig. P Fig. P Fig. P TC-170/TC-170 PD Upper shaft Assembly w/o PTO or hydraulic pump output...35 TC-170 Upper Shaft Assembly with PTO Output...37 TC-170 Upper Shaft Assembly with Hydraulic Pump Output...39 TC-170/TC-170 PD Intermediate Shaft Assembly without Lubrication Pump...41 TC-170/TC-170 PD Intermediate Shaft Assembly with Lubrication Pump...43 TC-170 Front Output Shaft Assembly...45 TC-170 Rear Output Shaft Assembly without Neutral...47 TC-170 Rear Output Shaft Assembly with Neutral...49 TC-170 PD 33/67 Lower Shaft Assembly...51 TC-170 PD 50/50 Lower Shaft Assembly...53 TC-170/TC-170 PD Single Acting Air Shift Cylinder Assembly...55 Parts not Illustrated...57 TO USE THIS PARTS MANUAL NOTE: 1. Refer to the view which illustrates the needed part. 2. Find the Required part in the view and then note the item number. 3. Locate the item number in the parts list for part number, description, and quantity. When ordering parts, specify model number, part number, serial number or other information that is on the Fabco nameplate located on the transfer case housing. Part numbers contained in this manual were in effect at the time the manual was approved for printing and are subject to change without notice or liability. Fabco Automotive Corporation reserves the right to change parts at anytime. -30-

3 UPPER SHAFT ASSEMBLY (Models without PTO or Hydraulic Pump Output) SEE FIG. P.5. INTERMEDIATE SHAFT ASSEMBLY (Models without Lubrication Pump) SEE FIG. P FRONT OUTPUT SHAFT ASSEMBLY SEE FIG. P.10. REAR OUTPUT SHAFT ASSEMBLY (Models without Neutral) SEE FIG. P.11. FIG P.1 - TYPICAL TC-170 BASIC TRANSFER CASE

4 UPPER SHAFT ASSEMBLY (Models with PTO Output) SEE FIG. P.6. INTERMEDIATE SHAFT ASSEMBLY (Models with Lubrication Pump) SEE FIG. P FRONT OUTPUT SHAFT ASSEMBLY SEE FIG. P.10. REAR OUTPUT SHAFT ASSEMBLY (Models with Neutral) SEE FIG. P.12. FIG P.2 -TYPICAL TC-170 BASIC TRANSFER CASE (SHOWN WITH NEUTRAL, PTO, AND LUBRICATION PUMP)

5 UPPER SHAFT ASSEMBLY SEE FIG. P.5. INTERMEDIATE SHAFT ASSEMBLY (Models with Lubrication Pump) SEE FIG. P LOWER SHAFT ASSEMBLY SEE FIG. P.13. FIG P.3 - TYPICAL TC-170 P.D. TRANSFER CASE (with 33/67 PROPORTIONAL DIFFERENTIAL)

6 UPPER SHAFT ASSEMBLY SEE FIG. P.5. INTERMEDIATE SHAFT ASSEMBLY (Models without Lubrication Pump) SEE FIG. P LOWER SHAFT ASSEMBLY SEE FIG. P.14. FIG P.4 - TYPICAL TC-170 P.D. TRANSFER CASE (with 50/50 PROPORTIONAL DIFFERENTIAL)

7 TC-170/TC-170 P.D. UPPER SHAFT ASSEMBLY Models without PTO or Hydraulic Pump Output. See Fig. P.5. ITEM PART NO. DESCRIPTION QTY. NOTE Locknut, 1 3/ Oil Seal Carrier Carrier Gasket Bearing Cup Bearing Cone Washer 1 ( 3.75 OD x 2.51 ID x.25 Thick ) Gear Shaft Woodruff Key Bearing Cone Bearing Cup Shim,.030 Coral A/R Shim,.015 Pink A/R Shim,.005 Blue A/R Shim,.002 Red A/R Cap Cap Cap, Screw, 7/16-14 x 1 1/4 Hex Head Washer, 7/16 Flat 16 Footnotes: 1. Models without lubrication pump. 2. Models with lubrication pump. 3. See service manual.

8 FIG P.5 - UPPER SHAFT ASSEMBLY Models without PTO or Hydraulic Pump Output

9 TC-170 UPPER SHAFT ASSEMBLY Models with PTO Output. See Fig. P.6. ITEM PART NO. DESCRIPTION QTY. NOTE ITEM PART NO. DESCRIPTION QTY. NOTE Locknut, 1 3/ Plate, Cover Oil Seal Gasket Carrier Gear, Clutch Collar Gasket Snap Ring Bearing Cup Shaft Bearing Cone Gear, Clutch Washer Bearing Cup and Cone Assy. 2 (3.75 OD x 2.51 ID x.25 Thick) Ring, Bearing Spacer, Gear Ring, Bearing Spacer, Shaft Ring, Bearing Spacer, Woodruff Key Ring, Bearing Spacer, Bearing Cone Ring, Bearing Spacer, Bearing Cup Ring, Bearing Spacer, Gear, Clutch Ring, Bearing Spacer, Shim,.030 Coral A/R Gasket Shim,.015 Pink A/R Carrier Shim,.005 Blue A/R Oil Seal Shim,.002 Red A/R Washer Housing, Declutch 1 (2.69 OD x 1.54 ID x.25 Thick) Cap Screw, Locknut, 1 1/ /16-14 x 2 1/4 12-pt. Head Cap Screw, 7/16-14 x 1 1/ Cap Screw 4 Hex Head 1/4-20 x 1/2 Hex Head Washer, 7/16 Flat 18 Footnotes: 1. See service manual. 2. Select one spacer ring. See service manual.

10 FIG P.6 - UPPER SHAFT ASSEMBLY Models with PTO Output

11 TC-170 UPPER SHAFT ASSEMBLY Models with Hydraulic Pump Output. See Fig. P.7. ITEM PART NO. DESCRIPTION QTY. NOTE ITEM PART NO. DESCRIPTION QTY. NOTE Locknut, 1 3/ Housing, Declutch Oil Seal Cap Screw, 7/16-14 x 2 1/ Carrier 1 12-pt. Head Gasket Cap Screw, 1/4-20 x 1/ Bearing Cup 1 Hex Head Bearing Cone Plate, Cover Washer Gasket 1 (3.75 OD x 2.51 ID x.25 Thick) Gear, Clutch Collar Gear Gear, Pump Drive, Shaft 1 SAE C Spline Woodruff Key Set Screw, 3/8-16 x 5/ Bearing Cone Locknut, 1/ Bearing Cup Gasket Gear, Clutch Plate, Pump Mounting Shim,.030 Coral A/R Bolt, 1/2-13 x 1 3/4 Hex Shim,.015 Pink A/R 1 Head (Pump Mounting) Shim,.005 Blue A/R Cap Screw, 7/16-14 x Shim,.002 Red A/R 1 Hex Head Cap Screw, 7/16-14 x 1 1/4 10 Hex Head Washer, 7/16 Flat 10 Footnotes: 1. See service manual. 2. The unit is shipped with the bolts listed. When mounting the pump, use longer grade 5 bolts if necessary.

12 FIG P.7 - UPPER SHAFT ASSEMBLY Models with Hydraulic Pump Output

13 TC-170/TC-170 P.D. INTERMEDIATE SHAFT ASSEMBLY Models without Lubrication Pump See Fig. P.8. ITEM PART NO. DESCRIPTION QTY. NOTE Vent Cap, Front Gasket Bearing Cup Bearing Cone Shaft Woodruff Key Gear Washer 1 (3.75 OD x 2.76 ID x.45 Thick) Shim,.030 Coral A/R Shim,.015 Pink A/R Shim,.005 Blue A/R Shim,.002 Red A/R Cap, Rear Cap Screw, 7/16-14 x 1 1/4 12 Hex Head Washer, 7/16 Flat 12 Footnotes: 1. See service manual.

14 FIG P.8 - INTERMEDIATE SHAFT ASSEMBLY Models without Lubrication Pump

15 TC-170/TC-170 P.D. INTERMEDIATE SHAFT ASSEMBLY Models with Lubrication Pump See Fig. P.9. ITEM PART NO. DESCRIPTION QTY. NOTE Vent Cap, Front Gasket Bearing Cup Bearing Cone Shaft Woodruff Key Gear Washer (3.75 OD x 2.76 ID x.45 Thick) Shim,.030 Coral A/R Shim,.015 Pink A/R Shim,.005 Blue A/R Shim,.002 Red A/R Cap, Oil Pump Mounting Spring, Oil Pump Oil Pump Cartridge Assembly Gasket, Oil Pump Ring, Oil Pump Shim, Oil Pump A/R Cap, Oil Pump Cap Screw, 7/16-14 x 1 1/4 Hex Head Washer, 7/16 Flat Cap Screw, 5/16-24 x 3" Hex Head Lock Washer, 5/16 6 Footnotes: 1. See service manual.

16 FIG P.9 - INTERMEDIATE SHAFT ASSEMBLY Models with Lubrication Pump

17 TC-170 FRONT OUTPUT SHAFT ASSEMBLY See Fig. P.10. ITEM PART NO. DESCRIPTION QTY. NOTE ITEM PART NO. DESCRIPTION QTY. NOTE Locknut, 1 3/ Gear, Clutch Collar Oil Seal Housing, Declutch Bearing Cone Gasket, Declutch Cover Bearing Cup Plate, Declutch Cover Carrier Cap Screw, 1/4-20 x 1/2, Gasket, Carrier 1 Hex Head Ring, Bearing Spacer, Shim,.030 Coral A/R Ring, Bearing Spacer, Shim,.015 Pink A/R Ring, Bearing Spacer, Shim,.005 Blue A/R Ring, Bearing Spacer, Shim,.002 Red A/R Ring, Bearing Spacer, Cap Screw, 7/16-14 x 2 1/4, Ring, Bearing Spacer, pt. Head Gear, Clutch Cap Screw, 7/16-14 x 1 1/4, Shaft 1 Hex Head Snap Ring 1 Footnotes: 1. Select one spacer ring. Refer to service manual. 2. Refer to service manual. 12/98

18 FIG P.10 - FRONT OUTPUT SHAFT ASSEMBLY Basic Transfer Cases (without Proportional Differential)

19 TC-170 REAR OUTPUT SHAFT ASSEMBLY Models without Neutral See Fig. P.11. ITEM PART NO. DESCRIPTION QTY Locknut, 1 3/ Gear Clutch Bearing Cup Bearing Cone Shaft Woodruff Key Gear Washer(3.75 OD x 2.51 ID x.25 Thick) Bearing Cone Bearing Cup Gasket Carrier Oil Seal Cap Screw, 7/16-14 x 1 1/4 Hex Head Washer, 7/16 Flat 10

20 FIG P.11 - TC-170 REAR OUTPUT SHAFT ASSEMBLY Models without Neutral

21 TC-170 REAR OUTPUT SHAFT ASSEMBLY Models with Neutral See Fig. P.12. ITEM PART NO. DESCRIPTION QTY. NOTE ITEM PART NO. DESCRIPTION QTY. NOTE Locknut, 1 3/ Shift Fork Gear, Clutch Shaft, Shifter Bearing Cup O-Ring, Shifter Shaft Bearing Cone O-Ring, Piston to Shaft Ring, Spacer Nylon Washer, Piston Stop Washer, Thrust Felt Wiper Gear, Sub-assembly Piston Shaft, Sub-assembly O-Ring, Piston Gear, Clutch Collar Washer, Shifter Shaft Ring, Inner 1 (.69 OD x.38 ID x.12 Thick) Bearing Cone Locknut, 3/ Bearing Cup O-Ring, Cap Ring, Outer Cap, Shift Cylinder Gasket Cap Screw, 1/4-20 x 3/ Carrier 1 Hex Head Oil Seal Cap Screw, 7/16-14 x 1 1/ Locknut, 1/ Hex Head Washer, 1/2 Flat Washer, 7/16 Flat 10 12/98

22 FIG P.12 - TC-170 REAR OUTPUT SHAFT ASSEMBLY Models with Neutral

23 TC-170 PD 33/67 LOWER SHAFT ASSEMBLY See Fig. P.13. ITEM PART NO. DESCRIPTION QTY. NOTE ITEM PART NO. DESCRIPTION QTY. NOTE Locknut, 1 1/ Gear, Planet, 10T Washer, Gear, Sun, 20T, 1 (2.25 OD x 1.28 ID x.19 Thick) (Front Output Shaft) Oil Seal 1 29 Cover Plate, Planet Gear Carrier, Oil Seal Internal Gear, 40T Gasket, Oil Seal Carrier Thrust Washer, Internal Gear Ball Bearing Assembly, Housing, Differential Case, 1 (Includes Snap Ring) Rear Carrier, Front Bearing Bearing Cone Gasket, Bearing Carrier Bolt, Differential Case Halves Gear, Clutch 1 35 Shoulder Screw, 3/ Retaining Ring Cap Screw, 3/8-16 X 1", Gear, Clutch Collar 1 12-pt. Head Housing, Differential Lockout Gasket, Housing Cap Screw, 1/4--20 x 1/2, Housing, Outer Differential 1 Hex Head Shaft, Rear Output Plate, Lockout Cover Bearing Cup and Cone Assy Gasket, Lockout Cover Ring, Bearing Spacer, Shim,.030 Coral A/R Ring, Bearing Spacer, Shim,.015 Pink A/R Ring, Bearing Spacer, Shim,.005 Blue A/R Ring, Bearing Spacer, Shim,.002 Red A/R Ring, Bearing Spacer, Locknut, Carrier, Rear Gear, Clutch Oil Seal, Rear Output Bearing Cup Locknut, 1 3/ Bearing Cone Cap Screw, 7/16-14 x 1 1/4, Locknut, 5/ Hex Head Gear, 50T, Lower Washer, 7/16 Flat Stud, 5/8-11 x 5/8-18 x 3" Cap Screw, 7/16-14 x 1 1/4, 10 23A Stud with Loctite 2 12-pt. Head Housing, Differential Case, Cap Screw, 7/16-14 x 2 1/4, 6 Frontt 12-pt. Head Dowel Pin, 1/2 Dia. x 1 1/4 Long Carrier, Planet Gears 1 Footnotes: 1. See service manual. 2. Select one spacer ring. Refer to service manual. 3. Part of Sub-Assembly. 12/98

24 -52- FIG P.13 - TC-170 PD 33/67 LOWER SHAFT ASSEMBLY

25 TC-170 PD 50/50 LOWER SHAFT ASSEMBLY See Fig. P.14. ITEM PART NO. DESCRIPTION QTY. NOTE ITEM PART NO. DESCRIPTION QTY. NOTE Locknut, 1 1/ Shaft, Front Output Washer, Thrust Washer, Side Gear 2 (2.25 OD x 1.28 ID x.19 Thick) Gear, Differential Side Oil Seal Gear, Differential Pinion Carrier, Oil Seal Thrust Washer, Pinion Gasket, Oil Seal Carrier Differential Spider Cross Ball Bearing Assembly, Housing, Differential Case, 1 (Includes Snap Ring) Rear Carrier, Front Bearing Bearing Cone Gasket, Bearing Carrier Bolt, Differential Case Halves Gear, Clutch Gasket, Housing Retaining Ring Housing, Outer Differential Gear, Clutch Collar Shaft, Rear Output Housing, Differential Lockout Bearing Cup and Cone Cap Screw, 1/4-20 x 1/2, 4 Assembly Hex Head Ring, Bearing Spacer, Plate, Lockout Cover Ring, Bearing Spacer, Gasket, Lockout Cover Ring, Bearing Spacer, Shim,.030 Coral A/R Ring, Bearing Spacer, Shim,.015 Pink A/R Ring, Bearing Spacer, Shim,.005 Blue A/R Carrier, Rear Shim,.002 Red A/R Oil Seal, Rear Output Locknut, Locknut, 1 3/ Gear, Clutch Cap Screw, 7/16-14 x 1 1/4, Bearing Cup 2 Hex Head Bearing Cone Washer, 7/16 Flat Locknut, 5/ Cap Screw, 7/16-14 x 1 1/4, Gear, 50T, Lower 1 12-pt. Head Stud, 5/8-11 x 5/8-18 x 3" Cap Screw, 7/16-14 x 2 1/4, Housing, Differential Case, Front 1 12-pt. Head Footnotes: 1. See service manual. 2. Select one spacer ring. Refer to service manual. 12/98

26 -54- FIG P.14 - TC-170 PD 50/50 LOWER SHAFT ASSEMBLY

27 TC-170/TC-170 PD SINGLE-ACTING AIR SHIFT CYLINDER ASSEMBLY All Models See Fig. P.15. ITEM PART NO. DESCRIPTION QTY Cap Screw, 1/4-20 x 3 3/4 Hex Head Cap, Shift Cylinder O-Ring, Shift Cylinder Tube, Shift Cylinder Locknut, 3/ Washer, Shifter Shaft (.69 OD x.38 ID x.12 Thick) O-Ring, Piston Piston Felt Wiper O-Ring, Piston to Shaft Spring Nylon Stop Ring Tube, Shift Cylinder Adapter Lock Wire Bolt, 7/16-20 x 1 1/2 Drilled Head Shift Fork Shaft, Shifter Switch, Indicator Light Washer, Copper Pin, Switch Actuating Welch Plug, 1" 1

28 FIG P.15 - SINGLE-ACTING AIR SHIFT CYLINDER ASSEMBLY All Models

29 TC-170/TC-170 PARTS NOT ILLUSTRATED ITEM PART NO. DESCRIPTION QTY. NOTE Housing, Transfer Case Name Plate, Serial Number Drive Screw, Name Plate Plug, 3/4 NPT Socket Head Plug, 1/4 NPT Socket Head Plug, 3/4 NPT Square Head (Oil Fill) Plug, 3/4 NPT Socket Head, Magnetic 1 The parts related to the lubrication piping are not covered in this manual due to the many different configurations. When replacing, use the old part for identification. Note however, that all fittings and hose assemblies are available from Fabco. Footnotes: 1. Quantity varies depending on model.

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