Transfer Cases 875 —— Specifications END PLAY Idler Shate Reur Output Shaft As Near As Poss, To 0.0” - As Near As Poss. To 0.0" Type oe eeeeeeecce Thickness Available Timken Model 221 iption Ne trunsfor case, mounted on and crossmember brackets be- tie main transmission assembly, fies » means for transmitting to the rear and/or front axles jwover take-off, A single eontrol Tnked to the gearshift lever, is ito select desired gear im the inser case. Mursheel-drive may be engaged engaged at any time without rar when transfer case Is in drive; however, in returning fsowheel-dvive from Zour-wheel- the accelerator may have to be momentarily, to relieve while shift is being made. Oil Seal Replacement {fit becomes necessary to replace we] in either the input or the or rear output shafts, perform folowing steps: Drain Iubricant from transfer ewe. SHIMS 2. Disconnect « Selective Fit vee 0,008" 0,005" 9,010" . 2.0" 50L1°50:60 Lbs. applicable drive- shaft, 8. Remove cotter pin and nut from 7 9. U-joint yoke. Use suitable puller arid remove U-joint from shaft, Remove cap screws attaching bearing cover; then remove cover and gasket. Drive out old sea] from bearing cover, Cast outer diameter of new seal with sealing compound and install it in bearing cover with lip facing inward. Using new gasket, replace bear- ing eover. NOTE: Make sure off passages ure aligned when in- stalling gasket and cover, Drive U-joint yoke on shaft and replace nut and cotter pin. Connect driveshaft. Replace lu- bricant, Shift gnd Control Rod Adjustment a. With crossbar disconnected, ad just both shift rod cleyjaes to Uistance of 2-9/32" fram center of pin hole fo end of shift rod, ‘then tighten jam nuts. Connect shift rod clevises. to crossbar with glevis and cotter pins. a Shift transfer. ease to 2awheel drive position” Disconnect’ « shift control rod from lever at adjustable clevis. Check elearanee between cros* bar and frame crossmember. If necessary, disconnect and read- just front drive shift rod clevis to obtain & minimum clearance of 3/18", Connect shift rod clovis to crossbar. Connect control rod to lever and shift transfer case to the “4-LO” position. Measure distance from center of clevis pin hole to bolt head. Tf necessary, disconnect and readjust shift control rod clevie to obtain a minimam elearagee of S11/16" (with 5 speed tranmission) or 4” (with 4-speed transmission) . Connect control rod clevix to shift lever. Disassembly Cover and Shift Red 1. Mount transfer case on a sufta- ble repair stand and drain Iu- bricant. 2. Position transfer ease shift rods in four-whee! low. 8. Remove nine eap screws attach- ing cover; then slide cover up- ward and lift to remove. NOTE: When removing cover, care should be taken not to lose de- tent balls and springs. 4. Remove detent balls und springs irom holes in ease and remove interlock pin from cover. 5. Cut lock wires; then remove shift fork set serews. 6. Using a brass drift, tap shift rods from case and lift out forks ag each rod is removed. Remove oil seals. Shaft Yokes and Deflector 1. Remove cotter pins and nuts from three U-jaint yokes. 2. Using suitable puller, remove U- Joint yokes, Idler Shaft 1. Remove cap screws attaching front and rear idler shaft bear- ing caps to case; then remove caps, oil seal and adjusting shims. Atiach shims to cap for reassembly. NOTE: Mark bear- ing cap with dye or prick punch for reassembly reference. They must be assembled to same loca-. tion from which they were re- moved. 2. Press or drive idler shaft out of case. Remove input shaft eon- stant mesh gear, spacer and low speed gear. 3 Bemave bearing cone and bear- ing cup. Front Output Shaft 1. Remove cap serews attaching front bearing eap; then remove cap, ofl seal and gasket, Pull front output shaft and bear- ing assembly from case, Remove bearing from shaft, using an arbor press. 2. Remave front sliding genr- 4. Remove cap screws attaching rear bearing eap; then remove cap and gasket. , 5. Remove snap-ring from front output gear; then remove sliding spacer. 6. Drive output gear inward out of bearing ; then lift out of case. Remove hearing. - "Transfer Cases 876 a Timken model 221 transfor ease (© GM.C} 1 Shift fork 17 Oil seal 33 Speedometer gear 49 Bearing cone 65 Front output 2 Shift rod 18 Cap screw 34 Bearing cup 50 Input shatt gear 66 Set screw 3 Oil seal 19 UsJoint yoke 35 Bearing cone 31 fdler shatt 67 Shift fork 4 €ap screw 20 Nut 36 Rear output gear 52 Spacer 68 Shift red 7 5 Lock washer 21 U-Joint yoke 37 Rear output shaft 53 Low speed gear 69 Front sliding ‘ eens cap 22 Oil-seal 28 Bearing cone = erin cone yOsF chi eit oe 39 Bearing cup jearing cup ont output s 23 Cap screw aring : § pane case 24 Flat cap screw 40 Adjusting shims a Sake ee 7 heating 10 Washer 25 Logk washer 41 Bearing Cap #36 Leck waste 11 Direct drive gear 26 Bearing cap 114A Input shaft gear 27 Gasket 12 input shaft * 28 Breather 13 Bearing 29 Cover 14 Adjusting shims 30 Interlock pin 15 Bearing cap 31 Spring 16 Lock washer 32 Detent ball Removing U-Joint yoke GMC} Removing bearing from idler shat {© GMC) 42. Lock washer 3 73 Bearing cap” 43 Cap screw ee 74 Lock washer 44 Cap’screw eo eal 75 Cap screw 45 Lock washer , é Song a aus he Wc Gasket 64 Bearing 7a wt 48 Bearing cup Rear Output Shaft Remove cap screws attaching Tear output bearing caps. Re- Move caps, gasket, of] seal and shims. Attach shims to cap for reassembly. NOTE: Mark bear-. ing caps with dye or prick pund for reassembly reference. They >» Must be assembled to same loca~ tion from which they were re * moved. “3 Removing snap-ring from front output gear (© &.M.C) 2. Remove speedometer gear rear output shaft; then pr drive shaft toward front of until shaft and bearing can removed. Lift out rear 01 shaft gear. 3. Remove bearing cone and ing cup. Input ‘Shaft 1, Remove cap screws atTransfer Cases 877 With 4-Speed Tronsmission shown) it 0 avicimum of 3.70" 3.5p, Transminsion) or @ of 25" twith &.Sp. Trans rar bearing cap; then remove ap. 2 Remove cap screws attaching front bearing cap; then remove cap and shims, Attach shims to cap for reassembly. Press.or drive out input shaft ,. toward front of case. Remove direct drive gear, slid- ing gear and thrust washer from inside case. Remove front’ hearing and vasher. Remoye other bearing from shaft. issombly . En assembly, it is important =e t all parts are cleaned and lubri- to preyent deterioration before it is placed in service. Use new fe oil seals, snap-rings and lock 8, Input Sheft 4, Press front bearing onto shaft with shielded side of bearing toward shoulder on. shaft. ‘usert shaft through opening in front of case and as shaft is be- fag'moved into position, instal? siding gear, washer, direct drive gat and washer. Install rear bearing on shaft with shielded side toward inside, ‘Install gasket “and bearing cap at rear of case. Tighten cap grews securely. Atiront of case, install heart pand shims. Use same thick- 8 of shims as removed during dgssembly. Install U-joint yoke- and nut. Tighten nut firmly, and install totter pin. Frame Cross a Front Drive 1 levis i ‘Shift Rod Cross Bor S-Ni 18 ‘ 228" \ ! 8 J] Hite a | | Shift Rod { ® ' 8 Clevis d i SHIFT DIRGRAM, Seen ut Vi wath A ia Welded—No_ Adjustment 1 wf ‘Shift Control With Trarsfer Case in o- ! Rod dition, clearance setween Crossbar | ond frame Crossmember should be; | Transfer onium oF 8 1 Gore Shift and control rad adjustment (@ G.M.C.) . Secure with cap screws. Rear Output Shaft 1. Press bearing cone onto rear output shaft. 2. Press or drive rear eutput shaft in case through shaft gear. 3. Press or drive bearing cup into case. Install bearing cap, using same thickness of shims that were removed. Tighten ..cap screws firmly. 4, At rear of shaft, press bearing cone onto shaft and bearing cup into ease. Install speedometer drive gear. 5. Install new oil seal in bearing cap; then install gasket and eap with screws. 6. Instal! U-joint yoke and secure with nut. Tighten nut firmly and install cotter pin. 7. Check end play of shaft, using dial indicator. Remove or add adjusting shims as required un- til end play is as near zero as possible, Front. Output Shaft 1. Place front output gear inside case; then install bearing*over | gear hub and inté position in case. 2. Press bearing onto,outpyy shaft. 3. As output shaft” ia- dpdtalled through opening in Front tase, sliding gear must be located on shaft as shaft is pushed into its proper position. . 4, Install new oil seal in bearing eap; then install gasket and cap with screws. 5. Install spacer on gear; then in- stall snap-ring. 6. Tastall: gasket and bearing cap. a n e a = uP ue : taching forks to rods. Install U-joint yoke and secure with nut. Tighten nut securely and install cotter pin, Idler Sheft Press bearing cone onto front end of idler shaft. Start idler shaft into front side of case and install low speed gear, spacer, constant mesh gear and bearing cone as shaft is pushed into position. Press bearing cups into case and over bearing cones. At rear of case, install bearing cap and gasket with cap screws. At front of case, install bearing eap and adjusting shims with cap bolts. NOTE: Make sure ad- justing shims used are same thickness as shims removed. Check end play of shaft, using dial indicator. Subtract or add adjusting shims as required un- til end play is as near to zero as possible. Cover and Shift Rod Install oil seals in cage. ‘Push shift rods into case’ with a so as not to damage oil is. Thstall shift forks on respective shift rods. Install set screws at- Twist safety wire around shift rods and then through hole in set serew. Insert detent balls and springs inte holes in-cage. . Slide interlock pin into bosses on inner surface of cover. Install gasket on case with sealing com- pound. Press end of cover down; then slide cover @pward. and press into position. Secure with cap screws,876 Transfer Cases ‘tual 14 15 161718 19 20 Wate jou = iil 21 33 > if 42.43 ‘50 | % Wa 4 ot 57 5B ay 97 it 62 63 6455 73747576 77 7% Timken model 221 transfer case (© G.M.C.) 1 Shift fork 17 Oil seal 33 Speedometer gear 49 Bearing cone 65 Front output @ 2 Shift rod 18) Cap acre 34 Bearing cup 50 Input shaft gear 66 Set screw 3 Oil seal 19 U-Joint yoke 35 Bearing cone 51 Idler shaft 67 Shift fork 4 Cap screw 20 Nut 36 Rear output gear 52 Spacer 68 Shift rod 5 Lock washer 21 U-Joint yoke 37 Rear output shaft 53 Low spged gear 69 Front sliding @ 6 Bearing cap 22 Oil seal 38 Bearing cone 54 Bearing cone 7 Gasket 23 Cap screw 39 Bearing cup 55 Bearing cup 70 Front output sh 8 Transfer case ap noni “ 56 Adjusting shims 71 Bearing i 24 Flat cap screw 40. Adjusting shims ; 9 Bearing ; 57 Bearing cap 72 Gasket 10 Washer 25 Lock washer 41 Bearing Cap © 58 Lock washer 11 Direct drive gear 26 Bearing cap 4 Lock washer 59 Cap screw 73 Bearing cap 11A Input shaft gear 27 Gasket a ae screw 60 Bearing cap 74 Lock washer 12 Input shaft 28 Breather iL scent 61 Gasket 75 Cap screw 13 Bearing 29 Cover goCraraset 62 Snap rin, i 14 Adjusting shims 30 Interlock pin 46 Bearing cap 33 Spacer * 6 Hat yoke 15 Bearing cap 31 Spring 47 Gasket 64 Bearing 78 Nut 16 Lock washer 32 Detent ball 48 Bearing cup