Fabco TC 180 Service Manual

SERVICE MANUAL
FABt:O TRANSfER CASE 625-0540
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FabcoTransferCase.com I 8 77. 776.4600 I 407.872.1901 I parts@eprogear.com
FABCO TC–180 TRANSFER

CASE
SERVICE MANUAL
FabcoTransferCase.com by Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 (877) 776-4600 / (407) 872-1901
SERVICE MANUAL 625-0540
Table of Contents
MODEL TC-180, Transfer Case.......…………………………………………...................………………..1.0
Introduction………………………………………………………………………………. ...........………...1.1
Assembly Views......…………….….…………………………………………………............ …….….…1.2
LUBRICATION......…………………………………………………………………………….............………2.0
Recommended Lubricants….………………………….......................................................................2.1
Inspection.....………………………………………….. …………………………….............……….……2.2
Oil Change....…..……………….….………………………………………………………...............….…2.3
Draining the Oil....……………………………………………………………….............…………………2.4
Refilling the Oil………………………………………………………………………………..................…2.5
Operating Temperature....………………………………………………..………………….............……2.6
CLEANING AND INSPECTION..……..……………………………………………………………...............3.0

Cleaning……………………………………………..............................................................................3.1
Drying and Corrosion Inhibition....………….. ………………………………………………….............3.2
Inspection....……………………………………………………………………………………….............3.3
GENERAL INSTRUCTIONS..………………………………………………………………………..............4.0
Safety………………………………………………………………………...……………………..............4.1
Assembly Precautions …………………………………………………...…………………............….…4.2
Removal………………………………………………………………..…………………………...............4.3
Installation……………………………………………………………………………………….................4.4
DISASSEMBLY………………………………………………………………………………………...............5.0
General Disassembly………………………………………………………………………….…..............5.1
Transfer Case Component Removal ……………………………………………………...............…5.2
PTO Shaft removal………………………………………………………………………………………….5.3
Input Shaft Removal……………………..……………………………………………….................…….5.4
Rear Output Shaft Removal………….......…………………………………................…………………5.5
Front Output Shaft Removal………………………..………………............…………………………….5.6
Intermediate Shaft Removal……………………………….............……………………..............…...…5.7
Subassemblies………………………………………………………………………………………………5.8
Input Shaft Disassembly……………………….………………………………….……………………..5.8.1

Intermediate Shaft Disassembly…………………..……………………………………….…………...5.8.2
Front Output and PTO Shaft Disassembly…………………………...………………………………..5.8.3
Rear Output Shaft Disassembly………………………...………………………….……….…………..5.8.4
Shift Shaft Disassembly..……………………………………………………………………………..….5.8.5
ASSEMBLY.….………………………………………………………………………………..............……….6.0
Assembly of Subassemblies……………………………………………………….............……..………6.1
Assembly of the Input Shaft……………………………………………………….................……...……6.2
Assembly of the Intermediate Shaft....…………………………………………...........……...........……6.3
Assembly of the Front Output and PTO Shaft………………………………………………...........…...6.4
Assembly of the Rear Output Shaft and Carrier………………………………...........………………...6.5
General Assembly…………………………………………………………………..............…………......6.6
Intermediate Shaft Installation……………………………………………….………………………….6.6.1

Rear Output Shaft Installation……………………………………………….…………………………..6.6.2
Front Output & PTO Shaft Installation………………………………………….………………………6.6.3
Input Shaft Installation…………………………………………………….……………..………...…….6.6.4
TORQUE SCIFICATIONS……………………….....................................................................................7.0
SEAL INSTALLATION INSTRUCTIONS………………………............................……………………….8.0
TOOLS.................................................................................................................................................9.0
ILLUSTRATED PARTS AND LIST..….………………………….….................……SEE PARTS MANUAL
1.0 MODEL TC-180, Transfer Case

1.1 INTRODUCTION
CORPORATION
FABCO Model 180 Transfer Case & Split Shaft PTO

The fabco Model '180 is a family of Transfer Case and Split Stiat Power Take offs wilh single-speed, three-stiaft,
constant mesh design. The new Model 180 is the tatest genera.tJon design replacing the Fabco Model 170 •and 175
The Model 180 features increased oil capacity, higher str.e11gt11 main housing, increased torque capacity lielic.al
gearing . ultra-high temperature seals and gaskets, revised declutching gearing and a proprietary Fabco lubncation
pump, yet refains same installation envelope of previous Fabco designs.
Ratings- Nominal •
15,000 Lb. Fl.
Torq.ue
18,000 Lb Ft (Through Shaft)
Horsepower 600 HP_
Input Speed 3 ,000 RPM
Ratio 1: 1 Standard. Confact Fabco for Optional Ratios
·Gear Type Helical. Case Hardened
Shaft Sizes
Input/Front & Rear Output 2 50 Inches, 10 Parallel Spline
Shaft Spacing (Drop) 1625 Inches
Sh1ft Mechanism Integral Air Cynnders
Bearings Tapered Roller
Lubrication System Pressurized & Splash
Lubricant SAE 50 or 75W90 GL4 MT-'1 Synthetic Gear Oil
Oil Capacity,. Nominal ·12.0 Quarts
Weight-,Dry 470 Lbs . approx.
Housing Precision Cast
• i'jll ratings nominal'. Actual capaciues deter1111nea based upon review of apphcauon data by rabco £11g111eenng
1.2 ASSEMBLY VIEWS
The New Fabco Model 180 Transfer Case & Split Shaft PTO
New high strength precis;on cast

housing. Hoos.ng hM thicker
section, enhanced material
properties and revised geometry
/ -~-·
to give max,mun1durabilny. Availab'e with a large range of
."'... ""'"' ~
Lifting bosses, hydraul~ pump PTO and SAE pump pod
suppon 1>o!Ses ono 011 r.1IIO"e
New coarse-pitch, high strength

forged helical gearing gives
increoMd torque & hotllepower
capacity while retaining qu et Retains same mounting pottem
performance. and dove shaft spacing as the
popular Fa~ Model 170 8
175, making customer
lntegrauon easy.
Fobco proprietary oil

pump for unproved
service pertom,ance
New ultro,high Milnory 111-thealre proven
temperature 011 seois, design.
goskets and o-rlngs.
Improved lubncalion
distribution at critlcal
shaft beMngs.
C~ llble will\
.oomn,~rctalty nvt11labl~
drive yoke, 8 flange$ Larger 011 sump for
Improved lubrlcatlon
Revised declutch gear
oooth orofilr througholll
f,1r op1m11:ed s~l~•1'Q
Porlorr\'IO<IO~.
Figure 1
INPUT >
FRONT
R R
< OUPUT OUTP UT p
TC-180 Transfer Case

SECTIONAL VIEW
Figure 2
PTO OIJTPlJT
TC-180 Transfer Case with Upper Rear PTO

SECTIONAL VIEW
Figure 3
2.0 LUBRICATION
2.1 RECOMMENDED LUBRICANTS

Draining is best accomplished after the
SAE 50 synthetic is recommended for on/off- vehicle has been operated briefly, allowing the
highway operation. oil to become warm and flow more freely.
Remove both drain and fill plugs. Allow the
1-
NOTE: EXTREME PRESSURE (EP) OILS ARE NO LONGER
RECOMMENDED FOR USE IN FABCO TRANSFER CASES.
UNDER CERTAIN OPERATING CONDITIONS THESE OILS
MIGHT FORM CARBON DEPOSITS ON GEARS AND SHAFTS.
housing to empty completely. Before the unit is
refilled, it should be thoroughly flushed with
clean flushing oil or kerosene.
The lube oil filter should be replaced
2.2 INSPECTION whenever the oil is changed. The filter element
The oil is to be maintained at the level of the is of a spin-on type. A film of clean oil should
fill plug at all times. Check at the following be applied to the rubber gasket of the new filter
intervals: element before installing. Do not over tighten.
Highway Service …………..………...1,000 Miles 2.5 REFILLING THE OIL
Off-Highway Service …………..……....40 Hours If the transfer case has been removed from
the vehicle for service, it is the best to refill the
With every oil change, the shift cylinder air oil after the unit has been reinstalled into the
lines and valves should be inspected for leaks vehicle.
and possible malfunctioning. Low pressure Clean and replace the drain plug and fill the
conditions can cause partial clutch engagement transfer case with the appropriate oil with the
which may result in premature wear or damage. vehicle on level ground. Fill the transfer case to
the level of the sight glass.
2.3 OIL CHANGE
2.6 OPERATING TEMPERATURE
The transfer case lubricant should be
changed on all new transfer cases after the first The operating temperature of the transfer
3,000 to 5,000 miles (on-highway), or the first case should not exceed 250°F (120°C).
40 hours (off-highway); thereafter oil changes Extensive operation at temperatures exceeding
should be done at the following intervals: 250°F will result in rapid brake down of the oil
and may shorten the transfer case life. If
On-Highway Service……...10,000-15,000 Miles reduction of operating speeds is not acceptable
then the case may have to be equipped with
Off-Highway Service………….....500-700 Hours external oil cooler to maintain the operating
temperature below 250°F.
The recommended oil change and inspection The following conditions may contribute to
periods are based on average use and excessive oil temperatures:
operating conditions that the unit may
encounter. It is suggested that the individual 1. A vehicle which is used in tropical or
owner make a periodic lab analysis of the desert conditions.
lubricant to determine contamination based on
the units specific operating conditions. With 2. A vehicle where extended body work or
this data, the oil change and inspection periods an accumulation of dirt and plant
can be better determined. material may shield the case from air
ventilation and circulation.
2.4 DRAINING THE OIL
3. A vehicle that is operated for extended
distances at high speed with the main
transmission in overdrive.
3.0 CLEANING AND INSPECTION
3.1 CLEANING
teeth. Shafts may be nicked or marked, or
Steam may be used for external cleaning of have damage threads. Parts which show any
completely assembled units. Care must be signs of damage should be repaired or
taken to ensure that water is kept out of the replaced.
assembly by sealing breather caps and other Inspect the oil pump. If any damage is
openings. noted, the pump assembly should be replaced
The transfer case housing which, is too as a unit.
large to conveniently clean with solvents, may Check all shift forks and slots in sliding
be immersed in a hot solution tank containing a clutches for wear or discoloration due to heat.
mild alkaline solution. Aluminum parts such as Check the engaging teeth for a partial
the carriers, caps, declutch housing, and air engagement wear pattern.
shift cylinder components must never be
cleaned in any type of alkaline solution. Parts NOTES
clean in a hot solution tank must be rinsed
thoroughly to prevent damage by traces of
alkaline material.
Parts with ground or polished surfaces,
such as bearings, gears, shafts, and oil pump
components should be clean with emulsion
cleaners or petroleum solvents. An alkaline
solution may damage the machined surfaces
and such cleaning methods should be avoided.
3.2 DRY AND CORROSION INHIBITION
Dry compressed air or clean, soft shop

towels should be used to dry parts after
cleaning. Bearings should never be spun dry
with compressed air.
Dried parts should be immediately coated
with a light oil or corrosion inhibitor to prevent
corrosion damage. Parts which are to be
stored should also be wrapped in heavy waxed
paper or plastic bags and kept dust-free.
3.3 INSPECTION
Prior to reassembly, parts which are to be

reused must be carefully inspected for signs of
wear or damage. Replacement of such parts
can prevent costly downtime at a future date.
All bearing surfaces, including roller
bearings cups and cones, should be examined
for pitting, wear, or overheating. Gears may
also show pits, as well as scoring and broken
4.0 GENERAL INSTRUCTIONS
4.1 SAFETY 4.2 ASSEMBLY PRECAUTIONS
The servicing and maintenance of 1. Read these instructions completely

components from any automotive vehicle before starting reassemble. Refer to
present possible hazards, every endeavor the appropriate exploded view in the
should be made to minimize the risk taken to parts manual.
successfully complete the task. For your
protection we offer these warnings and 2. All parts must be cleaned. The gasket
suggestions. surfaces must be free of oil gasket
material. Do not reuse old gaskets.
1. When working on, around, or under the
vehicle the parking brake should be 3. Bearing cups bores, shaft splines and
securely applied and all wheels should bearing mounting surface, should be
be blocked to prevent wheel coated with Lubriplate or equivalent.
movement. Do not rely on the vehicle This is necessary to reduce the
being in gear with a dead engine to possibility of galling.
prevent movement. All work should be
performed on a flat level surface free of 4. All used oil seals must be replaced and
loose material. the new oil seals should be coated with
Loctite 601 or equivalent on their outer
2. When working under a vehicle, it diameter prior to being installed in their
should be raised and supported with bores. The sealing lips should be
the appropriate frame stands or very coated with Lubriplate or the equivalent
secure blocking. to provide initial lubrication.
WARNING: NEVER WORK UNDER A VECHILE WHILE 5. All external cap screw should have
SUPPORTED ONLY ON A FLOOR JACK OR HOIST.
there threads coated with loctite.
3. Be sure any lifting equipment has 6. All threaded fasteners should be
adequate capacity to raise the vehicle tightened to the torque specified in the
or component being lifted. This torque specification section.
includes hydraulic floor jacks, and axle
support dollies, etc. The weight of 7. Any sharp edges on the seal diameter
Fabco components is given in the front of the universal joint yoke or
of the applicable service manual. companion flanges should be removed
with emery cloth and should be coated
4. Caution must be exercised when with Lubriplate or the equivalent on the
cleaning the component or underside of seal operating area prior to installation.
the vehicle. Compressed air should not
be used to blow dirt away as any 8. In many of the procedures, when a part
harmful contaminant material on the is assembled with a press fit, it is
bottom of the vehicle will be spread recommended that the part be heated
around the work area. prior to installation. The part should be
placed in an oven and heated to no
Appropriate solvents and cleaning solutions more that 300°F. Excessive heat my
can be used in accordance with their labeling change the metallurgical properties of
instructions or by referring to the Material the part. Heated components should
Safety Data Sheet (MSDS) that is available for be allowed to cool to room temperature
each cleaner. Approved protective eyewear, before end float measurements are
gloves, masks, and clothing should always be made.
worn.
CAUTION: ALTHOUGH FABCO DOES NOT may require that one side be jacked up
RECOMMEND ITS USE IN TRANSFER CASES, IF
FORMED-IN-PLACE GASKET IS USED FOR REPAIRS.
in order to achieve sufficient clearance
EXTREME CAUTION MUST BE EXERCISED TO to place the transfer case between the
PREVENT THE COMPOUND FROM ENTERING frame rails.
BEARINGS, OIL GALLERIES, AND PASSAGES OR
TAPPED HOLES. ALL BEADS MUST BE KEPT SMALLER
THAN 1/8 INCH DIAMTER. 3. Raise the transmission jack to properly
locate the transfer case.
4.3 REMOVAL 4. Connect transfer case mounting. Since

mounting designs vary, consult vehicle
1. Remove fill and lower drain plugs and service manual.
drain gear lubricant.
5. Connect the drivelines, the speedometer
2. Disconnect wire leading to indicator light cable, and the shift cylinder air lines.
switch and temperature sensor, if used.
6. Connect the indicator light and
3. Disconnect and tag shift cylinder air temperature sensor wires.
lines.
7. Fill the housing with the appropriate
4. Disconnect speedometer cable. lubrication to the correct level and install
the oil fill plug.
5. Disconnect drivelines at flanges or
yokes. 8. Road test the vehicle and check the
transfer case for leaks around seals and
6. Position a transmission jack of suitable gaskets.
capacity beneath the transfer case. The
transfer case must be seated on the NOTES
jack in a safe and firm position.
7. Disconnect transfer case mounting at

the rubber shock insulators. Since
mounting designs vary, consult the
vehicle service manual.
8. After making sure that all mounting and

connections to the transfer case are
disconnected, lower the transfer case
gradually to the floor. It is imperative
that the transfer case is ALWAYS safely
positioned on the transmission jack to
safeguard the transfer case from falling
off the jack. Remove the transfer case
from beneath the vehicle. It may be
necessary to jack the truck up to allow
room to remove the transfer case.
4.4 INSTALLATION
1. Place the transfer case onto the

transmission jack, preferably lifting by
means of the eye bolts.
2. Position the transmission jack

underneath the vehicle. Some vehicles
5.0 DISASSEMBLY
Disassembly and assembly of the Fabco TC-180 Transfer Case with PTO is a relatively simple
procedure which can be made easier by the use of some very simple tooling. Details of all tooling
required are given in the tooling section (9.0) for manufacture in your own facilities or Fabco Automotive
may be contacted for a price and availability.
5.1 GENERAL DISASSEMBLY Be sure to use the correct procedure for each
shaft assembly. In some procedures, a similar
1. After removing the transfer case from procedure for a different shaft is called out.
the vehicle, thoroughly clean the
exterior. 1. Remove oil strainer. See Figure 5.
2. Remove the drain plug and drain the oil.
3. Mount the transfer case in a suitable

fixture. The fixture should be such that
the case can be rotated so that either its
front or its rear is facing upward. A
transfer case mounted in a typical fixture
is shown in Figure 4.
Figure 5
2. Remove the four hoses. Remove oil

filter from the oil filter bracket. See
Figure 6.
Figure 4
4. Remove the oil pump assembly, and

gasket.
5.2 TRANSFER CASE COMPONENT

REMOVAL Figure 6
For purposes of this manual, a TC-180 with 3. Remove the four bolts securing the filter
PTO contains five shaft assemblies: Input, bracket, then the filter bracket itself. See
Intermediate, Front Output, Rear Output, and Figure 7.
PTO shaft assembly.
Figure 9
6. See Section 5.8.5 for removal of the air

shift cylinders from the declutch
Figure 7 housings.
4. Remove the three indictor light switches 5.3 PTO Shaft removal
and washers located on the front side of
the transfer case attached to the
housing on the FRONT OUPUT SHAFT,
the transfer case’s back side on the
declutch housing, and the rear output
carrier. See Figure 8.
Figure 10
Figure 8
To remove the PTO shaft assembly and
5. Remove the three switch actuating pins
declutch housing, refer to section 5.6 “Front
with a pencil magnet. See Figure 9.
Output Shaft Removal” for similar procedure.
5.4 INPUT SHAFT REMOVAL 5.5 REAR OUTPUT SHAFT REMOVAL
Figure 11 Figure 12
1. If PTO declutch housing or cap has 1. Position the transfer case with its rear
been removed, also remove shim pack end facing upward.
on rear side. Keep the shims together
with the PTO declutch housing or cap to 2. Remove the ten cap screws and
facilitate reassembly. washers securing the rear output carrier
to the transfer case housing.
2. Carefully rotate the TC over so that the
front side is facing upward. The input 3. Mark the position of the carrier to
shaft can slide downwards as it has housing with chalk as it needs to be
some play between the housing and the reassembled in the same position.
gear, and it is only held by the bearing
cup that is no longer constraint by the 4. Remove the carrier and shaft assembly
PTO declutch housing or cap. by lifting on the shaft yoke. Discard the
gasket. See Figure 13.
3. Remove the ten cap screws and
washers securing the front input carrier
to the housing.
4. Remove the input carrier and shaft

assembly by lifting on the shaft yoke.
Discard the gasket.
Figure 13
5.6 FRONT OUTPUT SHAFT REMOVAL 6. Remove the air shift piston nut. Exercise
caution as the piston is spring loaded.
Remove the washer, piston, spring, and
the nylon stop ring.
7. Cut and remove the safety wire on the

shift fork bolts and remove the bolts.
See Figure 16.
Figure 14
1. Position the transfer case with its front

end facing upward.
Figure 16
2. Remove the four cap screws securing
the declutch housing cover plate. 8. Remove the shift shaft. It may be
necessary to carefully pry open slightly
3. Remove the eight cap screws and the slot in the shift fork to free the shaft.
washers securing the carrier to the Lift out the shift collar and the shift fork.
declutch housing. See Figure 17.
4. Mark the position of the carrier to

housing with chalk as it needs to be
reassembled in the same position.
5. Lift off the shaft assembly. Discard the

carrier gasket. See Figure 15.
Figure 17
9. Remove the six 12-point cap screws

securing the declutch housing to the
transfer case housing. Retain shims
together with the housing to facilitate
reassembly. Remove the bearing cup
from the transfer case housing.
10. Do not remove the freeze plug from the

shift shaft bore in the declutch housing
Figure 15 unless necessary.
5.7 INTERMEDIATE SHAFT REMOVAL cap. Remove the cap and discard the
gasket.
6. Remove the front bearing cup by pulling

upwards on the intermediate shaft
assembly.
7. The gear and the rear bearing cone both

have a press fit to the intermediate
shaft. Therefore, a puller will be
necessary to remove the shaft if
damage is to be avoided. (A sketch
depicting a suitable fabricated puller is
illustrated in Figure 20.)
STEEL TUBING
6.o·o.o . x 1/4 WALL x 4.0 LONG.
HEX NUT
ANO WASHER.
Figure 18
On Models not equipped with a lubrication

pump, begin the procedure at Step 4.
1. Position the transfer case with its rear

STEEL Pl.ATE
end facing upward. 3/4• THICK.
DRILLEO HOLE
TO CLEAR ROD.
2. Remove the four cap screws and 516-11 OR 314-16

THREAOEO ROO
washers securing the oil pump and r LONG.
remove it. Discard the gasket. Figure 20
3. Remove six cap screws securing the 8. To prevent damage, do not allow the
intermediate shaft cap. Remove cap. bearing cone assembly or the gear to
See Figure 19. drop inside the case as the shaft is
being pulled out. Remove the shaft,
gear, spacer, and bearing cone
assembly.
9. Rotate the transfer case over so that its

rear end is facing upward.
10. Remove the six cap screws and

washers securing the rear cap to the
transfer case. Remove the cap, shim
pack, and rear bearing cup. Keep the
shims together with the cap to facilitate
reassembly.
Figure 19 This concludes the general disassembly.
4. Position the transfer case with its front
end facing upward.
5. Remove the six cap screws and

washers securing the front intermediate
5.8 SUBASSEMBLIES PRESS
During a normal overhaul, it is neither

necessary nor desirable to completely
disassemble the shaft assemblies. The bearing
cone assemblies and the drive train gears are
installed with a press fit to the shaft and their
unnecessary removal only increases the
likelihood of damage. The same applies to the
bearing cups installed in the carriers.
Parts should be cleaned with emulsion cleaners

or petroleum solvents. To avoid damage, Figure 22
alkaline solutions should not be used.
4. To remove the rear bearing cone
5.8.1 INPUT SHAFT DISASSEMBLY assembly, support under the cone with a
bearing separator and press the shaft
through the cone. See Figure 23.
e?
Remove the shaft key only if necessary.
'.--~-
Figure 21
1. Remove the input yoke (or companion

flange) retaining locknut with an impact
wrench. Slide off the clutch gear if Figure 23
provided on the rear side. Slide the input
yoke (or flange) off the shaft on the input 5.8.2 INTERMEDIATE SHAFT DISASSEMBLY
side.
2. Lift off the input carrier assembly. lnilerml!Cllale Shall
Remove the oil seal from the carrier and

discard. Remove the bearing cup from
the carrier only if it is to be replaced. It is
not necessary to disassemble the shaft
assembly any further unless one or
more of the components remaining are Figure 24
to be replaced.
It is not necessary to disassemble the
3. Place the shaft assembly in a press so intermediate shaft assembly unless a
that the rear of the gear is supported component is to be replaced.
and the press arbor bears against the
threaded end of the shaft. See Figure 1. To remove the bearing cone assembly,
22. Remove the front bearing cone support under the cone with a bearing
assembly, the spacer washer, and the separator and press to shaft through the
gear. cone. See Figure 25.
PRESS
2) Remove the yoke (or companion flange)
retaining locknut with an impact wrench.
Slide the yoke (or flange) off the shaft.
3) Place the shaft assembly in a press

such that the face of the clutch gear is
supported and the press arbor bears
against the threaded end of the shaft.
See Figure 28. Be sure that the outer
diameter of the snap ring will clear the
support. Remove the carrier assembly,
Figure 25 the inner bearing cone assembly, the
bearing spacer ring, and the clutch gear.
2. Remove the shaft key only if necessary.
5.8.3 FRONT OUTPUT AND PTO SHAFT

DISASSEMBLY
Front Oulj}ti.t 5/Blt
PTO 01Jt:p1Jt Sh..--rl\
Figure 26 Figure 28
1) To facilitate reassembly, the end float of 4) Remove the oil seal from the carrier and
the shaft should be checked prior to discard. Lift out the remaining bearing
disassembly. Install a dial indicator with cone assembly. Remove the bearing
a magnetic base as pictured in Figure cups from the carrier only if they are to
27. Lift upward on the carrier and note be replaced.
the amount of end float.
5) Remove the snap ring from the shaft
only if it or the shaft is to be replaced.
5.8.4 REAR OUTPUT SHAFT DISASSEMBLY

WITHOUT NEUTRAL
ear Output Shilft v.itlnout Neutral
Figure 27
Figure 29
PRESS
1) Remove the yoke (or companion flange)
locknut with an impact wrench. Slide the
yoke (or flange) off the shaft.
2) Lift off the rear carrier assembly.

Remove the oil seal from the carrier and
discard. Remove the bearing cup from
the carrier only if it is to be replaced.
Steps 3, 4 and 5 are necessary only if one or

more components remaining are to be
replaced.
3) Remove the front clutch gear retaining

locknut with an impact wrench. See
Figure 30. Slide off the clutch gear.
Figure 31
5) To remove the remaining bearing cone

assembly, support under the cone with a
bearing separator and press the shaft
through the cone. See Figure 32.
PRESS
Figure 30
4) Place the shaft assembly in a press so

that the gear is supported and the press
arbor bears against the yoke-end of the
shaft. See Figure 31. Remove the
bearing cone assembly, the spacer
washer, and the gear. Remove the shaft
key only if necessary. Figure 32
5.8.5 REAR OUTPUT SHAFT DISASSEMBLY the gear and note the amount of end
WITH NEUTRAL float.
Rea r Output Shaft with Neutral
Figure 34
Figure 33
7) Remove the clutch gear retaining
1) Remove the yoke (or companion locknut on the other side of the shaft
flange) locknut on output side with an with an impact wrench and slide off the
impact wrench. Slide the yoke (or clutch gear. See Figure 35.
flange) off the shaft.
2) Remove the four cap screws securing

the shift cylinder cap to the carrier.
Remove the cap and the nylon piston
ring. Discard the cap O-ring.
3) Remove the piston retaining locknut and

washer. A wrench on the shift fork may
be necessary to prevent the shaft from
turning.
4) Lift the rear carrier assembly off the

shaft and slide the shift fork from the
clutch gear. Remove the oil seal from
the carrier and discard. Remove the
bearing cup from the carrier only if it is
to be replaced.
Figure 35
5) Remove the piston and the nylon stop
ring from the carrier. Discard all O- Steps 8, 9, and 10 are necessary only if one
rings. or more components remaining are to be
replaced.
6) To facilitate reassembly, the gear end
float on the shaft should be checked 8) Place the shaft assembly in a press so
prior to further disassembly. Install a that the gear is supported and press
dial indicator with a magnetic base as arbor bears against the yoke-end of the
pictured in Figure 34. Lift upward on shaft to remove the bearing cone
assembly, the spacer washer, and the remove the plate and gasket. See
gear. See Figure 36. Figure 38.
PRESS
'°7
Figure 38
2. Remove bolt safety wire and bolts. See

Figure 39.
Figure 36
9) To remove the remaining bearing cone

assembly, slide the clutch collar towards
the thrust washer and support under the
cone with a bearing separator and press
the shaft through the cone. See Figure
37.
Figure 39
PFIU S 3. Remove four Cap Screws, then the shift

shaft cap. See Figure 40.
£1.
Figure 37
Figure 40
10) Slide off clutch collar gear.
For steps 4-8, use Figure 41 for reference.
5.8.6 SHIFT SHAFT DISASSEMBLY (PTO
AND FRONT OUTPUT)
1.
1. Remove the four plate screws holding
the plate to the declutch housing. Then
Figure 41
4. Remove the nut and washer.
5. Take out the piston shift and stop. Figure 42
6. Remove compression spring. 8. Take out the shift shaft.
7. Uncase the shift cylinder adapter. 9. Remove the fork shift together with the
See Figure 42. clutch collar gear.
6.0 ASSEMBLY
Make sure all parts are clean, dry and lint free. Any traces of storage wax or paper should be
removed. Leave bearings and cups in their wrapper, until ready to use. Do not handle parts any more
than necessary.
Unless indicated otherwise, part mating surfaces should be given a light coat of lubricant.
Lubriplate is acceptable. A substitute may be used using a mixture of chassis grease and 30W engine
oil. The mix should be thin enough to apply with a small brush.
6.1 ASSEMBLY OF SUBASSEMBLIES
In the following assembly procedures, it is

assumed that the various shaft assemblies
were completely disassembled. Skip any step
that refers to a part that is already assembled.
Refer to section 4.2 in this manual for assembly
precautions.
6.2 ASSEMBLY OF THE INPUT SHAFT
e::?
.rm~· Figure 44
lll)OiS!dt 11<U.~1ear!'TO
CAUTION: WHEN A PART IS
, -=- ASSEMBLED WITH A PRESS FIT, IT IS
RECOMMENDED THAT THE PART BE
HEATED PRIOR TO INSTALLATION IN A
SUITABLE OVEN AT A TEMPERATURE
NO GREATER THAN 300°F.
Figure 43
3. Invert the input shaft and install the
1. Install a new oil seal and bearing cup in heated gear, the spacer, and the heated
the input shaft carrier. If removed, bearing cone. See Figure 45.
install a new key in the input shaft.
2. Heat and install the bearing cone

assembly against the shoulder on the
non-threaded end of the input shaft.
See Figure 44.
Figure 45
4. Place the carrier into position and slide CAUTION: WHEN A PART IS
the yoke (or companion flange) onto the ASSEMBLED WITH A PRESS FIT, IT IS
shaft. Install the yoke retaining locknut. RECOMMENDED THAT THE PART BE
For convenience, the nut may be HEATED PRIOR TO INSTALLATION IN A
torqued after the shaft assembly has SUITABLE OVEN AT A TEMPERATURE
been installed in the transfer case NO GREATER THAN 300°F.
housing.
THIS CONCLUDES THE ASSEMBLY OF THIS CONCLUDES THE ASSEMBLY OF

THE INPUT SHAFT. THE INTERMEDIATE SHAFT.
6.3 ASSEMBLY OF THE INTERMEDIATE 6.4 ASSEMBLY OF THE FRONT OUTPUT

SHAFT AND PTO SHAFT
lllliermedlale Sil.all
~ - Front OJt !lt Sh
Figure 46
1. If removed, reinstall the keys into the

key-ways of the intermediate shaft.
2. Heat the bearing cones and

intermediate gear and press onto the Figure 48
intermediate shaft. See Figure 47.
1. Install the snap ring on the shaft.
2. Place the shaft in an upright position,

with the fine-threaded end up, to protect
the shaft threads and splines.
3. Install the clutch collar gear onto the

shaft such that the counter bore in the
gear fits over the snap ring. Ensure
clutch collar gear is mated against snap
ring before installing bearing cone.
4. Heat the inner bearing cone and install

it against clutch gear.

ASSEMBLED WITH A PRESS FIT, IT IS
Figure 47 HEATED PRIOR TO INSTALLATION IN A
The remainder of the intermediate shaft NO GREATER THAN 300°F. HEATED
assembly must be done inside of the transfer COMPONENTS MUST BE ALLOWED TO
case housing during the shaft installation COOL BEFORE END FLOAT
procedure. MEASUREMENTS ARE MADE.
9. Mount a dial indicator on the shaft as

5. Install the inner bearing spacer ring. shown in Figure 51.
The bearing cone spacer ring is a
select-fit part that is used to adjust the
shaft end float. If the end float checked
prior to disassembly was within
specification (.003 to .008 in.) and no
parts were replaced, the original bearing
spacer ring should provide the correct
end float on reassembly. See Figure
49.
Figure 51
10. Lift the carrier up and note the indicated

shaft end float on the dial indicator. If
the end float is not within specification
(.003 to .008 in), it will be necessary to
disassemble the shaft and repeat steps
5-8 using a bearing spacer ring of a
different thickness.
11. Remove the yoke (or companion flange)

and install the oil seal.
Figure 49
6. Press the bearing cups into the carrier. ASSEMBLED WITH A PRESS FIT, IT IS
7. Put the carrier onto the shaft and then HEATED, PRIOR TO INSTALLATION, IN A
the heated outer bearing cone. See SUITABLE OVEN AT A TEMPERATURE
Figure 50. NO GREATER THAN 300°F. HEATED
COMPONENTS MUST BE ALLOWED TO
COOL BEFORE END FLOAT
MEASUREMENTS ARE MADE.
THIS CONCLUDES THE ASSEMBLY OF

THE FRONT OUTPUT AND PTO SHAFT.
Figure 50
8. Do not install oil seal at this time. Slide

the yoke (or companion flange) onto the
shaft. Install and torque the locknut.
6.5 ASSEMBLY OF THE REAR OUTPUT CAUTION: WHEN A PART IS

SHAFT WITH NEUTRAL AND CARRIER ASSEMBLED WITH A PRESS FIT, IT IS
HEATED, PRIOR TO INSTALLATION, IN A
NO GREATER THAN 300°F. HEATED
COMPONENTS MUST BE ALLOWED TO
,--------- ----· ____..., COOL BEFORE END

MEASUREMENTS ARE MADE.
FLOAT
2. Lubricate the thickest part of the shaft

'•--%
I .,._
and the inner surface of the gear. See
,------- -----------____l
Figures 54 and 55.
I
I
IL--
rrier
Figure 52 Figure 54
1. Install the clutch collar gear onto the

shaft. See Figure 53.
Figure 55
3. Then align and install the gear on the

shaft. See Figure 56.
Figure 53
Figure 56
4. Install a thrust washer against the gear

Figure 58
assembly followed by the small spacer.
8. Start creating the shift-fork assembly by
5. Heat and install the bearing cone
sliding shift-fork onto the shorter side of
assembly on the shaft against the
the shifter-shaft. Place a flat washer on
spacer. Then place the clutch gear on
top of the fork and screw in a locknut
top of the bearing assembly. See Figure
using Loctite 272 or equal. See Figure
57.
59.
Figure 59
9. Place an O-ring on the 3/8 threaded

side of the shifter-shaft and attach the
shift-fork assembly onto the clutch
Figure 57
collar. See Figure 60.
6. Apply Loctite 290 or equal to the locknut
and tighten to the required torque.
7. Invert shaft assembly and install the

other bearing cone on top of the clutch
collar. Place the large spacer above the
bearing. See Figure 58.
12. Use Loctite 620 or equal on the outer

diameter of the oil seal and press it into
the carrier. See Figure 63.
Figure 60
10. Press the bearing cup into the carrier.

See Figure 61.
Figure 63
13. Align the carrier and place it on top of

the bearing cone. Grease up the area
between the shift-shaft and the carrier.
14. Place a nylon washer on to the shift-fork

assembly. Soak the felt strip in gear oil
and install it in the inner groove of the
piston. Slip an O-ring around the outer
groove before sliding it onto the nylon
washer. The end of the piston with the
counterbore should be facing outward.
Place a washer on top of the piston and
screw in a locknut using loctite 272 or
equal. Place another nylon washer
above the piston. Put an O-ring onto the
Figure 61
shift cylinder cap. See Figure 64.
11. Place an O-ring into the insert on the
carrier. See Figure 62.
Figure 64
15. Screw in the shift cylinder cap using four

cap screws again using Loctite 272 or
equal. See Figure 65.
Figure 62
19. Screw in a fitting onto the shift cylinder

cap. See Figure 68.
Figure 65
16. Slip the yoke (or companion flange) onto

the shaft and secure it with a locknut.
17. Insert the indicator switch actuation pin Figure 68

into place. The rounded end of the pin
must face inward. See Figure 66. THIS CONCLUDES THE ASSEMBLY OF
THE REAR OUTPUT SHAFT WITH
NEUTRAL. _ _ _ I
6.6 GENERAL ASSEMBLY
6.6.1 INTERMEDIATE SHAFT INSTALLATION
Figure 66
Figure 69
18. Install the switch using a new copper
washer. Torque to specification. See 1. Position the transfer case with its front
Figure 67. end (nameplate) facing upward.
2. Heat the intermediate shaft gear and

lower it into the transfer case housing
through the lower or upper shaft bore.
Position the gear against the rear of the
housing in line with the intermediate
shaft bores. See Figure 70.
Figure 67
6. Rotate the TC over so that its rear end

is facing upward. To prevent damage,
reach in the case and support the
intermediate shaft assembly as the unit
is rotated.
7. Slip the spacer washer over the

intermediate shaft against the gear.
Heat and install the remaining bearing
cone assembly against the spacer
washer. See Figure 73.
Figure 70
3. Quickly lower the intermediate shaft

assembly through the gear. Be sure that
the gear is firmly seated against the
shaft shoulder.
4. Place one of the bearing cups into its

bore in the front of the housing. Install
the front intermediate shaft cap with a
new gasket. See Figure 71.
Figure 73
8. Place the bearing cup into its bore.

Install the rear cap with the original shim
pack. See Figure 74.
~ - ~
'
, .... - --- ,,
'
Figure 71
,._.... ~
~- -
5. Install the six cap screws and washers.

Torque to specification. See Figure 72.
Figure 74
9. Install the six cap screws and washers.

Torque to specification.
10. Rotate transfer case over such that its

shafts are horizontal. Mount a dial
indicator such that the indicator tip rests
against the end of the shaft. See Figure
75.
Figure 72
6.6.2 REAR OUTPUT SHAFT

INSTALLATION
frea,1 "'I.. rt -..dhuu l t-leLJl,.,I

OLIJp.,I ...,
R.,,,,Ot_,, I"'' fmnwlh "" ,r

a_
Figure 75
11. Pry the gear up and down several times

--1®t -,~,, I \
i
_______ __ ________________ ___ _I

to be sure that the bearing cups are
seated. Note the indicated shaft end
float on the dial indicator. If the end float \_~-~. u-_-_J}~lii]-l
is not within specification (.003 to .008
in), the shim pack should be removed
and replaced with a combination of
shims which will provide the proper end
t_ 11)11Jt---
float. Be sure to recheck the end float
after replacing with new shims. Figure 77
12. Install the oil pump using a gasket and 1. Position the transfer case with its front
four bolts. Torque to specifications. See end (nameplate) facing upward.
Figure 76.
2. If removed, install the freeze plug into
the shifter shaft bore of the front
declutch housing. Use non-hardening
sealer to prevent an oil leak.
3. Insert the front bearing cup into its bore

and place the original shim pack on top
of the bearing cup. Ensure that the
declutch in the next step compresses
the bearing cup and shims into place.
See Figure 78.
Figure 76
installed in the vehicle as in Figure 79.

4. Position the front declutch housing on Install the ten cap screws and washers
the transfer case such that the shifter to secure the carrier to the TC housing.
shaft bores are directly to the left of the Torque to specification.
lower shaft bore (as viewed when the
unit is installed in the vehicle). See 9. Rotate transfer case over such that its
Figure 79. shafts are horizontal. Mount a dial
indicator on the shaft as shown in
Figure 81. Pry the rear output shaft up
and down several times to be sure that
the front bearing cup is seated. Note the
indicated shaft end float on the dial
indicator. If the end float is not within
specification (.003 to .008 in.), the shim
pack should be removed and replaced
with a combination of shims which will
provide the specified end float. Be sure
to recheck the end float after replacing
with new shims.
" ../"Ill
- ;~
Figure 79
~e· .~~.. •·
_,· ..........
5. Install the six 12-point cap screws and
torque to specification.
' ·~
· -,~, .. ·
~--
-4. -- : . •'
6. Rotate the TC over so that its rear end Jt..
is facing upward.
,.
~~
7. Position a new gasket on the TC
housing and lower the rear output shaft
assembly into place .See Figure 80. [ - ....... . WiJL,.~····
Figure 81
6.6.3 FRONT OUTPUT AND PTO SHAFT

INSTALLATION
Front 0Jt !It Sh
Figure 82
Figure 80
1. In order to install the Front output shaft it
8. The word “TOP” on the rear carrier must is necessary to reinstall the shift shaft
be toward the top of the transfer case as assembly.
between the two bolt heads. See Figure

2. Position the transfer case with its front 85.
end (name plate) upward. The front
declutch housing should already be
installed. See Figure 79.
3. Slide the shift fork onto the clutch collar

and place the two parts, as a unit, into
the declutch housing. See Figure 83
Figure 85
6. Install a new piston-to-shaft O-ring over

the threaded portion of the shaft. Slide
the spring over the shaft. Place the
nylon stop ring over the shaft and
spring. Install a new piston O-ring in the
outer groove in the piston. Soak the air
shift piston felt strip in gear oil and install
it in the inner groove. See Figure 86.
0 -Ring
~~ ~
Figure 83 F
e~<7~~S~Sl:
4. The clutch collar and fork must be
installed in the right direction, so that the
0 -Ring @~-~ SI ·11 Cylicler Adapter
-~~~
\ Spnng 11 .
shift fork bolts can be installed on the 0 -Ring

machined side. See Figure 84.
Lociut Washer -------------
Figure 86
7. Position the piston on the shifter shaft.

The end of the piston with the
counterbore should be facing outward.
Push the piston down to compress the
spring and install the shifter shaft
washer and locknut. Torque the nut to
specification. See Figure 87.
Figure 84
5. Insert the shift shaft into position. Rotate

the shift shaft so that the slots lineup
with the bolt holes in the shift fork. Install
the (2) shift fork bolts and torque to
specification. Install the lock wire
10. Secure the assembly with the four long

cap screws. Torque to specification. See
Figure 90.
Figure 87
8. Install the declutch housing cover with a

new gasket. Torque the four cap screws
to specification. See Figure 88.
Figure 90
11. Insert the indicator switch actuation pin

into place. The rounded end of the pin
must face inward. See Figure 91.
Figure 88
9. Slip the air shift cylinder into position

over the piston. Install a new O-ring on
the shift cylinder cap and insert into the Figure 91
cylinder. See Figure 89.
12. Install the switch using a new copper
washer. Torque to specification. See
Figure 92.
Figure 89
1. Position the transfer case with its rear

end facing upward.
2. Insert the rear bearing cup into the bore

on the housing. Use the original shim
pack. See Figure 95.
Figure 92
Figure 95
13. Using a new gasket and eight cap
screws, install the front output shaft 3. Align and install the PTO declutch
assembly to the declutch housing. housing or cap on to the transfer case
Torque to specification. See Figure 93. housing. See Figure 96.
Figure 96
4. Install the six 12-point cap screws and

torque to specification.
Figure 93
5. Rotate the transfer case over so that its
6.6.4 INPUT SHAFT INSTALLATION
front end is facing upward.
e::? 6. Make sure that the rear bearing cup is

still in place. Position a new gasket on
£]}~ the transfer case housing and lower the
shaft assembly into place. See Figure
97
Figure 94
8. Rotate transfer case such that the shafts

are horizontal. Mount a dial indicator on
the shaft as shown in Figure 99.
Figure 97
7. Align and install the carrier. The word

“TOP” on the carrier must be toward the
top of the transfer case as installed in
the vehicle. Torque the ten cap screws Figure 99
and washers to specification. See
Figure 98. 9. Pry the gear up and down several times
to be sure that the bearing cups are
seated. Note the indicated shaft end
float on the dial indicator. If the end float
is not within specification (.003 to .008
in), the shim pack should be removed
and replaced with a combination of
shims which will provide the proper end
float. Be sure to recheck the end float
after replacing with new shims.
10. To install the PTO Shaft turn the TC

housing so its rear is facing up and
follow steps in section 6.6.3, starting
with step 3.
Figure 98
7.TORQUE SPECIFICATIONS
70 FT-LBS 50 FT-LBS
10 FT-LBS
800 FT-LBS
70 FT-LBS
70 FT-LBS
25 FT-LBS
800 FT-LBS
80D FT-LBS
70 FT-LBS
ALL TORQUE (LB.-Ff.) VALUES ARE FOR DRY UNLUBRICATED THREADS, AND
SHOULD BE WITH IN 10% OF THE VALUES SHOvVN.
Figure 100
50 FT-LBS
70 FT-LBS
800 FT-LBS
500 FT-LBS
70 FT-LBS
800 FT-LBS
800 FT-LBS
70 FT-LBS
70 FT-LBS
ALL TORQUE (LB-FT) VALUES ARE FOR DRY UNLUBRICATED THREADS

AND SHOULD BE W ITH IN 10% OF THE VALUES SHOWN.
Figure 101
25 FT-LBS
45 FT-LBS 8 FT-LBS
ADDITIONAL TORQUE SPECIFICATIONS
OIL FILL PLUG.....................................50 FT-LBS
OIL LEVEL SIGHT PLUG.................... 50 FT-LBS
TEMPERATURE SENSOR PLUG........ 25 FT-LBS
OIL FILTER BRACKET. ....................... 15 FT-LBS
ALL TORQUE (FT-LBS) VALUES ARE FOR DRY UNLUBRICATED THREADS, AND
SHOULD BE WITH IN 10% OF THE VALUES SHOWN.
Figure 102
8.0 SEAL INSTALLATION INSTRUCTIONS
and seal driver (866-0888). For Front

1. Drop driveline to access the yoke or output location, use seal (732-0466),
flange retaining nut. and seal driver (866-0861).
2. Remove the retaining nut from the SEAL
shaft. Input sectional view shown in
Figure 103. w
r::1
>-<
V)
lJ
z>-<
IY
o_
V)
w
r::1
>-<
V)
NUT 0..
>-<
_J
f-
YOKE SEAL JOURNAL Cl)
::J
YOKE BEVEL SPRING i:::i
SEAL DRIVER
Figure 103
Figure 104
3. Pull the yoke straight off the shaft.
Inspect yoke to verify it is in good 8. Place seal driver on shaft. For input
condition. If excessive wear is noted, location, drive seal into bore with old
the yoke should be replaced. If any nut (688-0738). For Front and Rear
burrs are found on the seal journal or output locations, drive seal into bore
beveled corner they should be with old retaining nut. Seal driver will
removed if the yoke is to be reinstalled. stop when seal is fully seated against
shoulder on housing carrier bore. Input
CAUTION: CARE MUST BE EXERCISED TO AVOID DRIVE
YOKE DAMAGE.
installation shown in Figure 105.
4. Pull the old seal from the housing

carrier. For the input location, remove
three screws and washers prior to seal
removal.
5. Clean the seal bore in the housing
carrier where the old seal had been
located.
6. Inspect the new seal to verify that the
lip material is intact and in good
condition free of any nicks or marks.
Also check the outside diameter of the
new seal for any dents or burrs. If any
are found the seal should not be
installed. Figure 105
7. Place seal on seal driver tool as shown 9. For input location, remove old nut and
in Figure 104 below, ensuring the seal driver. Re-install screws and
spring side is facing away from the washers. For Front and Rear output
seal driver tool. For top input and rear locations, remove old nut and seal
output locations, use seal (732-0467), driver.
10. Lubricate the shaft splines, seal lips, 13. For input location, install a new unused
drive yoke seal journal, and drive yoke retaining locknut. Torque the nut to
bevel with transfer case fluid. 800 lb-ft. For Front and Rear output
locations, install a new unused
11. Start the drive yoke on the shaft, retaining locknut. Torque the nut to
ensuring the splines are properly 800 lb-ft.
engaged and slide freely. Push the
drive yoke onto the shaft until it seats. 14. Rotate the drive yoke by hand to check
for binding or interference.
12. Check dust lip to ensuring that it is not
folded under and is facing out. If dust 15. Recheck oil level and fill as necessary.
lip is folded under pull out drive yoke ½
to 1 inch, rotate and push-in reseating
drive yoke. Repeat until dust lip is
correctly installed.
9.0 TOOLS
Details of tooling to facilitate the servicing of the Fabco TC-180 Transfer Case.
Service tools may be manufactured to these drawings or Fabco Automotive may be contacted for
pricing and availability.
The manufacture of these tools should be carried out by professional machinists and certified welders,
following typical and good workmanship procedures and safe practices.
A
B
C'
4
I
4.474
¢ 4.478
----'--
3
SECTION A-A
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Figure 106
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:;;: - - - - i
....--------il1-------~...
. ., _ _ - tCAf 'nEllncNI' - f'7!11SII
OIL SEAL
732-0466
CO! DRIVER, SEAL,

CJ',!
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L~\.1111£.U IIR(\/'E, LNEaKlaC till. 'MSSl
TC-180
= - :riCIILC
FULL IMW. 01 P/fff H.IIIICI
----- m-- 866-0861

O<IET
co "" I
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Figure 107
SERVICE MANUAL
- - - 0 4.50 -----;
- -0 3.50 - -----I
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.so,
Figure 108
R.0 6
.03 x 45· CHAMFER

3 PLCS. OUTSIDE
2 PLCS. INSIDE
866-0751 SETUP SLEEVE, REAR OUTPUT SHAFT
625-0540

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SERVICE MANUAL

FABt:O TRANSfER CASE 625-0540

Brought to you by:

FabcoTransferCase.com I 8 77. 776.4600 I 407.872.1901 I parts@eprogear.com

FABCO TC–180 TRANSFER

CLEANING AND INSPECTION..……..……………………………………………………………...............3.0

Input Shaft Disassembly……………………….………………………………….……………………..5.8.1

Intermediate Shaft Installation……………………………………………….………………………….6.6.1

SEAL INSTALLATION INSTRUCTIONS………………………............................……………………….8.0

ILLUSTRATED PARTS AND LIST..….………………………….….................……SEE PARTS MANUAL

1.0 MODEL TC-180, Transfer Case

FABCO Model 180 Transfer Case & Split Shaft PTO

Ratio 1: 1 Standard. Confact Fabco for Optional Ratios

·Gear Type Helical. Case Hardened

Sh1ft Mechanism Integral Air Cynnders

Bearings Tapered Roller

Lubrication System Pressurized & Splash

Lubricant SAE 50 or 75W90 GL4 MT-'1 Synthetic Gear Oil

Oil Capacity,. Nominal ·12.0 Quarts

Weight-,Dry 470 Lbs . approx.

Housing Precision Cast

1.2 ASSEMBLY VIEWS

New high strength precis;on cast

New coarse-pitch, high strength

Fobco proprietary oil

TC-180 Transfer Case

TC-180 Transfer Case with Upper Rear PTO

2.1 RECOMMENDED LUBRICANTS

Highway Service …………..………...1,000 Miles 2.5 REFILLING THE OIL

3.0 CLEANING AND INSPECTION

3.2 DRY AND CORROSION INHIBITION

Dry compressed air or clean, soft shop

Prior to reassembly, parts which are to be

4.0 GENERAL INSTRUCTIONS

4.1 SAFETY 4.2 ASSEMBLY PRECAUTIONS

The servicing and maintenance of 1. Read these instructions completely

4.3 REMOVAL 4. Connect transfer case mounting. Since

7. Disconnect transfer case mounting at

8. After making sure that all mounting and

1. Place the transfer case onto the

2. Position the transmission jack

2. Remove the drain plug and drain the oil.

3. Mount the transfer case in a suitable

2. Remove the four hoses. Remove oil

4. Remove the oil pump assembly, and

5.2 TRANSFER CASE COMPONENT

6. See Section 5.8.5 for removal of the air

5.4 INPUT SHAFT REMOVAL 5.5 REAR OUTPUT SHAFT REMOVAL

4. Remove the input carrier and shaft

7. Cut and remove the safety wire on the

1. Position the transfer case with its front

4. Mark the position of the carrier to

5. Lift off the shaft assembly. Discard the

9. Remove the six 12-point cap screws

10. Do not remove the freeze plug from the

6. Remove the front bearing cup by pulling

7. The gear and the rear bearing cone both

On Models not equipped with a lubrication

1. Position the transfer case with its rear

2. Remove the four cap screws and 516-11 OR 314-16