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<strong>Transfer</strong> <strong>Case</strong> Parts<br />
<strong>Ford</strong><br />
Mercury<br />
Lincoln<br />
®Autry Enterprises Ltd.<br />
2012
CONTENT INDEX<br />
TRANSFER CASE TYPE SERIES PAGE<br />
BW1345 2 SPD 4WD TC1345 2<br />
BW1350 2 SPD 4WD TC1350 4<br />
BW1354 2 SPD 4WD TC1354 8<br />
BW1356 2 SPD 4WD TC1356 12<br />
BW1359 NONE 2WD TC1359 14<br />
BW4403 AWD 4WD TC4403 15<br />
BW4404 1 SPD 4WD TC4404 16<br />
BW4405 2 SPD 4WD TC4405 18<br />
BW4406 2 SPD 4WD TC4406 20<br />
BW4407 2 SPD 4WD TC4407 22<br />
BW4410 1 SPD 4WD/AWD TC4410 24<br />
BW4411 2 SPD 4WD/AWD TC4411 26<br />
BW4416 2 SPD 4WD TC4416 28<br />
NP203F 2 SPD 4WD TC203F 30<br />
NP205F 2 SPD 4WD TC205F 34<br />
NP208F 2 SPD 4WD TC208F 36<br />
NV271F 2 SPD 4WD TC271F 38<br />
NV273F 2 SPD 4WD TC273F 40<br />
Dana 20F 2 SPD 4WD TC20F 42<br />
Dana-21 2 SPD 4WD TC21 44<br />
Dana 24 2 SPD 4WD TC24 45<br />
DanaModel-28 2 SPD 4WD TC28 46<br />
INDEX<br />
TKC-0011<br />
course<br />
Time-Sert®<br />
Master Kit (USS)<br />
Includes 1/4-20<br />
5/16-18/3/8-16<br />
7/16-14/1/2-13<br />
(20 each inserts)<br />
TKC-0021<br />
fine<br />
Time-Sert®<br />
Master Kit (SAE)<br />
Includes 1/4-28<br />
5/16-24/3/8-24<br />
7/16-20/1/2-20<br />
(20 each inserts)<br />
TKC-1002<br />
course<br />
Time-Sert®<br />
Master Kit<br />
(Metric USS)<br />
Includes M5x0.8<br />
M6x1.0/M8x1.25<br />
M10x1.5mm<br />
M12x1.75mm<br />
(20 each inserts)<br />
TKC-1003<br />
fine<br />
Time-Sert®<br />
Master Kit<br />
(Metric)<br />
Includes M5x0.8<br />
M6x1.0/M8x1.25<br />
M10x1.5mm<br />
M12x1.75mm<br />
(20 each inserts)<br />
TKC-1208-CMK<br />
course<br />
Master Kit<br />
(USS coarse)<br />
Includes inserts<br />
installation tools<br />
taps (1/4-20<br />
5/16-18/3/8-16<br />
7/16-14/1/2-13)<br />
TKC-1221-MMK<br />
course<br />
Master Kit (metric)<br />
Includes inserts<br />
installation tools<br />
taps (5x0.8<br />
6x1.0/8x1.25<br />
10x1.25mm<br />
10x1.5mm)<br />
© 2012 Autry Enterprises Ltd. i
VEHICLE TO TRANSMISSION INDEX<br />
INDEX<br />
MODEL NAME ENGINE YEAR TRANSFER CASE PAGE<br />
FORD/PICKUP<br />
Aerostar V/6 3.0L 90-97 DanaModel-28 46<br />
Bronco various 66-77 Dana 20F 42<br />
Bronco various 78-79 NP205F 34<br />
Bronco various 80-86 NP208F 36<br />
Bronco various 87-93 BW1356 12<br />
Bronco II various 83-93 BW1350 4<br />
Bronco II V/6 2.9L 84-90 BW1359 14<br />
Early trucks/vans/suv’s varoius 62-72 Dana 24 45<br />
Early trucks/vans/suv’s various 71-89 NP205F 34<br />
Early trucks/vans/suv’s various 72-79 NP203F 30<br />
Early trucks/vans/suv’s various 74-76 Dana-21 44<br />
Econoline 250 various 87-97 BW1356 12<br />
Econoline 250/250 SD various 99-08 NV271F 38<br />
Econoline 250/250 SD various 99-08 NV273F 40<br />
Econoline 350 variuos 87-97 BW1356 12<br />
Econoline 350 SD various 99-08 NV271F 38<br />
Excursion various 99-08 NV273F 40<br />
Expedition various 97-02 BW4406 20<br />
Expedition various 01-05 BW4416 28<br />
Explorer various 91-99 BW1354 8<br />
Explorer various 95-01 BW4405 18<br />
Explorer various 96-03 BW4404 16<br />
Explorer various 99-01 BW4403 15<br />
Explorer 5.0L V/8 02-06 BW4410 24<br />
Explorer 4.0L V/6 02-06 BW4411 26<br />
Explorer Sport/Sport Trac various 00-05 BW1354 8<br />
F-100 various 03-04 BW4416 28<br />
F-150 various 80-91 BW1345 2<br />
F-150 various 80-86 NP208F 36<br />
F-150 various 87-96 BW1356 12<br />
F-150 various 97-04 BW4406 20<br />
F-150 various 03-04 BW4416 28<br />
F-250 various 80-91 BW1345 2<br />
F-250 various 80-86 NP208F 36<br />
F-250 various 96-97 BW4404 16<br />
F-250 L/6 4.9L V/8 7.5L 96-97 BW4407 22<br />
F-250 various 97-99 BW4406 20<br />
F-250 various 99-08 NV271F 38<br />
F-250 Super Duty various 99-08 NV271F 38<br />
F-250/250 Super Duty various 99-08 NV273F 40<br />
F-350 various 80-87 BW1345 2<br />
F-350 various 80-86 NP208F 36<br />
F-350 various 96-97 BW4404 16<br />
F-350 V/8 7.3L 96-97 BW4407 22<br />
F-350 various 99-08 NV271F 38<br />
F-350 Super Duty various 99-08 NV271F 38<br />
F-350/350 Super Duty various 99-08 NV273F 40<br />
F-450/550 Super Duty various 99-08 NV271F 38<br />
Ranger various 83-93 BW1350 4<br />
Ranger various 91-98 BW1354 8<br />
LINCOLN<br />
Navigator various 99-02 BW4406 20<br />
Navigator various 01-05 BW4416 28<br />
ii<br />
© 2012 Autry Enterprises Ltd.
VEHICLE TO TRANSMISSION INDEX<br />
MODEL NAME ENGINE YEAR TRANSFER CASE PAGE<br />
MERCURY<br />
Mountaineer various 97-03 BW4404 16<br />
Mountaineer various 99-01 BW4403 15<br />
Mountaineer 5.0L V/8 02-06 BW4410 24<br />
Mountaineer 4.0L V/6 02-06 BW4411 26<br />
TKC-1208-FMK<br />
fine<br />
Time-Sert®<br />
Master Kit (SAE)<br />
Includes (1/4-28<br />
5/16-24/3/8-24<br />
7/16-20/1/2-20)<br />
TKC-0140<br />
1/4-20<br />
Inch Repair Kit<br />
Time-Sert®<br />
Includes drill bit<br />
counter bore/tap<br />
installation driver<br />
(5 inserts)<br />
INDEX<br />
TKC-0561<br />
5/16-18<br />
Inch Repair Kit<br />
Time-Sert®<br />
Includes drill bit<br />
counter bore/tap<br />
installation driver<br />
(5 inserts)<br />
TKC-1012<br />
M10x1.25<br />
Metric Repair Kit<br />
Time-Sert®<br />
Includes drill bit<br />
counter bore/tap<br />
installation driver<br />
(5 inserts)<br />
TKC-1208-104<br />
1/4-20<br />
Repair Kit (USS coarse)<br />
Includes inserts<br />
installation tool/tap<br />
TKC-1208-105<br />
5/16-18<br />
Repair Kit (USS coarse)<br />
Includes inserts<br />
installation tool/tap<br />
TKC-1208-106<br />
3/8-16Kit<br />
Repair Kit (USS coarse)<br />
Includes inserts<br />
installation tool/tap<br />
TKC-1208-107<br />
7/16-14<br />
Repair Kit (USS coarse)<br />
Includes inserts<br />
installation tool/tap<br />
© 2012 Autry Enterprises Ltd. iii
BW1345•1345<br />
45 60 105 106 46<br />
107 108 109 110<br />
112 113 63 114 64<br />
115<br />
BW1345<br />
A<br />
120<br />
121<br />
input<br />
shaft<br />
66<br />
plug<br />
126 127<br />
ring<br />
gear<br />
131<br />
locking<br />
plate<br />
133<br />
68<br />
shift<br />
hub<br />
range<br />
140 210<br />
sun<br />
gear<br />
143 144 250 146<br />
planetary<br />
148<br />
4 70<br />
B<br />
output<br />
122 shaft<br />
123<br />
rear<br />
pump<br />
pins & spring<br />
125<br />
retainer/<br />
support<br />
pump<br />
134<br />
2<br />
35<br />
drive<br />
gear<br />
hub speedo<br />
mode gear<br />
slider<br />
yoke<br />
nut<br />
filter<br />
drive chain<br />
156<br />
150 72 5 151 152 155<br />
73 157<br />
C<br />
20<br />
161<br />
165<br />
230<br />
232<br />
nut<br />
168 169<br />
yoke<br />
235 237<br />
174<br />
171<br />
shield<br />
output<br />
shaft<br />
front<br />
180 75<br />
driven<br />
gear<br />
181<br />
24<br />
D<br />
160<br />
21<br />
front<br />
case half<br />
184<br />
80<br />
range<br />
fork<br />
185<br />
170<br />
190 191<br />
187<br />
186 189 192<br />
195<br />
193<br />
194<br />
mode<br />
fork<br />
10<br />
175<br />
196<br />
197<br />
200<br />
85<br />
rear<br />
case half<br />
203<br />
204<br />
220<br />
speed<br />
sensor<br />
BW1345<br />
TC1345<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal BW1345 1 80-91 AE TK-1345<br />
n/i Kit, gasket/seal BW1345 1 80-91 AE K105-910<br />
GASKETS AND RUBBER COMPONENTS<br />
B2 Hose, oil pump BW1345 1 80-91 n/a TC1356-203<br />
n/i Gasket, adapter housing BW1345 1 80-91 04130678 13591<br />
METAL CLAD SEALS<br />
D20 Seal, metal clad front input 1 80-91 E3TZ-7B215-H 205-17502<br />
D21 Seal, metal clad front output shaft 1 80-91 E0TZ-7B215-B 205-18662<br />
D24 Seal, metal clad rear output 1 80-91 n/a 205-18994<br />
FILTERS<br />
B35 Filter, oil pump BW1345 1 80-91 n/a TC1356-050<br />
BUSHINGS<br />
A45 Bushing input shaft (front) 1 80-91 n/a TC1345-160<br />
2 © 2012 Autry Enterprises Ltd.
BW1345•1345<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
BUSHINGS (CONTINUED)<br />
A46 Bushing input shaft (rear) 1 80-91 n/a TC1345-161<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A60 Washer, thrust input shaft (front) 1 80-91 n/a TC1345-122<br />
A63 Washer, thrust sun gear 1 80-91 E0TZ-7D484-C TC1345-193<br />
A64 Washer, thrust sun gear 1 80-91 E0TZ-7D484-C TC1345-193<br />
B66 Bearing, caged rear output (rear) 1 80-91 n/a B2012<br />
B68 Washer, thrust drive sprocket 1 80-91 n/a TC1345-129<br />
D75 Bearing, ball .671” 1.377” id 2.837” od rear output 1 80-91 C8TZ-7025-C 6207N<br />
D80 Bearing, ball .671” 1.377” id 2.837” od front output shaft 1 80-91 C8TZ-7025-C 6207N<br />
D85 Bearing, caged front output (middle) 1 80-91 n/a B2812<br />
HARD PARTS<br />
A105 Shaft, front input BW1345 1 80-91 n/a TC1345-170<br />
A106 Plug, soft BW1345 1 80-91 n/a TC1345-171<br />
A107 Snap ring ring gear in case 1 80-91 n/a TC1345-172<br />
A108 Gear, ring BW1345 1 80-91 n/a TC1345-173<br />
A109 Plate, locking BW1345 2 80-91 n/a TC1345-174<br />
A110 Snap ring BW1345 1 80-91 n/a TC1345-177<br />
A113 Hub, range shift BW1345 1 80-91 E0TZ-7100-C TC1345-120<br />
A114 Gear, sun BW1345 1 80-91 n/a TC1345-180<br />
A115 Planetary assembly BW1345 1 80-91 E0TZ-7A398-B TC1345-110<br />
B121 Shaft, rear output BW1345 1 80-91 n/a TC1345-184<br />
B126 Retainer, support BW1345 1 80-91 n/a TC1345-186<br />
B127 Snap ring support retainer in housing 1 80-91 n/a TC1345-187<br />
B131 Pump, oil assembly BW1345 1 80-91 n/a TC1356-200<br />
B133 Retainer, oil pump BW1345 1 80-91 n/a TC1356-206<br />
B134 Clamp, oil pump hose BW1345 1 80-91 n/a TC1356-204<br />
B140 Sprocket, drive BW1345 1 80-91 n/a TC1345-188<br />
B143 Sleeve, mode (outer) BW1345 1 80-91 n/a TC1345-190<br />
B144 Hub, mode BW1345 1 80-91 n/a TC1345-191<br />
B148 Nut, rear output yoke BW1345 1 80-91 n/a TC1345-196<br />
C150 Nut, front output yoke BW1345 1 80-91 n/a TC1345-197<br />
C155 Shaft, front output BW1345 1 80-91 n/a TC1345-201<br />
C156 Sprocket, driven BW1345 1 80-91 n/a TC1345-204<br />
D161 Housing, front case BW1345 1 80-91 n/a TC1345-215<br />
D181 Housing, rear case BW1345 1 80-91 n/a TC1345-240<br />
TRANSFER CASE CHAINS<br />
B290 Chain, drive 86 links 1.500” wide (RJ) BW1345 1 80-83 E0TZ-7A029-B HV-013<br />
B290 Chain, drive 84 links 1.250” wide (RP) BW1345 1 82-91 E2TZ-7A029-A HV-012<br />
SHIFT FORKS AND PADS<br />
D230 Pad (nylon) range fork 2 80-91 1345-235-001 TC1345-28<br />
D232 Fork range 1 80-91 n/a TC1345-23<br />
D235 Pad (nylon) mode fork 2 80-91 1345-235-001 TC1345-28<br />
D237 Fork mode 4 80-91 n/a TC1345-24<br />
SPEEDO GEARS<br />
B250 Gear, speedo drive BW1345 1 80-91 n/a TC1345-270-R<br />
NOTES<br />
BW1345<br />
© 2012 Autry Enterprises Ltd. 3
BW1350•1350<br />
25<br />
95<br />
96 98<br />
55 56 99 58 100<br />
101<br />
102 60 45<br />
104<br />
105<br />
106<br />
111 113<br />
BW1350<br />
A<br />
94<br />
vent<br />
bearing<br />
retainer<br />
sun<br />
gear<br />
planetary<br />
input<br />
shaft<br />
output<br />
range 107<br />
shaft<br />
slider 105<br />
rear<br />
pump<br />
pins & spring<br />
pump<br />
3<br />
40<br />
115<br />
290<br />
126<br />
127<br />
128<br />
129<br />
130<br />
131<br />
133<br />
64<br />
134<br />
330 136<br />
137<br />
66<br />
5 140<br />
filter<br />
B<br />
drive<br />
sprocket<br />
lock-up<br />
collar<br />
reduction<br />
hub<br />
mode<br />
hub<br />
Manual Shift<br />
speedo<br />
gear<br />
yoke<br />
nut<br />
C<br />
drive chain<br />
145<br />
146 147 148 149<br />
150<br />
152<br />
295 154 68 332<br />
156<br />
lock-up<br />
collar<br />
reduction<br />
hub<br />
mode<br />
hub<br />
clutch<br />
housing<br />
Electric Shift<br />
magnetic<br />
clutch<br />
speedo<br />
gear<br />
yoke<br />
8 69 160<br />
nut<br />
D<br />
164 72 10<br />
165<br />
yoke<br />
183<br />
166 167 168 170 180 181 75 182 184 185<br />
76 186<br />
shield<br />
bolt on<br />
yoke<br />
u-joint<br />
output<br />
shaft<br />
front<br />
slip yoke<br />
output<br />
shaft<br />
front<br />
bearing<br />
retainer<br />
driven<br />
sprocket<br />
E<br />
190 195<br />
ring gear<br />
196<br />
28 192 80<br />
300 302<br />
202<br />
range<br />
fork<br />
203<br />
204<br />
305 307<br />
208<br />
mode<br />
fork<br />
217 218 220<br />
221<br />
216<br />
215<br />
209<br />
210<br />
roller<br />
211 212<br />
225 226<br />
shift rail<br />
detent<br />
spring<br />
12<br />
Manual Shift<br />
88<br />
280 281<br />
33<br />
nut<br />
282<br />
283<br />
297<br />
14<br />
4WD<br />
sensor<br />
front<br />
case half<br />
315 320 317 322<br />
rear<br />
242 247<br />
250 251<br />
case half<br />
243 248<br />
range 244 mode 249 shift rail<br />
fork fork<br />
296<br />
260 261 262 263 87 30<br />
15<br />
298<br />
speed<br />
sensor<br />
shift<br />
shaft<br />
torsion<br />
spring<br />
shift<br />
cam<br />
Electric Shift<br />
electric<br />
shift motor<br />
BW1350<br />
TC1350<br />
4 © 2012 Autry Enterprises Ltd.
BW1350•1350<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
K37 Kit, bearing/gasket/seal manual/electric shift 1 83-93 AE TK-1350<br />
K37 Kit, gasket/seal manual/electric shift 1 83-93 AE K105-915<br />
GASKETS AND RUBBER COMPONENTS<br />
A3 Hose, oil pump BW1350 1 83-93 1356-034-001 TC1356-203<br />
n/i Gasket, adapter adapter housing to transfer case 1 83-93 M353317A 13594<br />
METAL CLAD SEALS<br />
A25 Seal, metal clad front input shaft 1 83-93 E3TZ-7B215-H 205-17502<br />
E28 Seal, metal clad front output shaft (manual shift) 1 83-93 E3TZ-7B215-D 205-15900<br />
E28 Seal, metal clad front output shaft 1 83-93 F3TZ-7B215-A 205-16043<br />
E30 Seal, metal clad shift shaft 1 83-93 1300-044-001 TC1350-140<br />
E33 Seal, metal clad rear output shaft 1 83-93 F3TZ-7B215-A 205-16043<br />
FILTERS<br />
A40 Filter, oil pump BW1350 1 83-93 E0TZ-7A098-AA TC1356-050<br />
BUSHINGS<br />
A45 Bushing front input shaft (rear) 1 83-93 n/a TC1350-159<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A55 Bearing, ball .628” 1.773” id 2.950” od front input shaft (front) 1 83-93 E3TZ-7025-B 6009N<br />
A58 Washer, thrust sun gear (front) 1 83-93 E3TZ-7B066-A TC1350-132<br />
A60 Bearing, caged (cup) front input shaft (middle) 1 83-93 BCE-1816 TC1350-135<br />
A64 Bearing, ball .628” 1.180” id 2.435” od output shaft (middle) 1 83-93 E3TZ-7025-A 6206N<br />
C68 Bearing, ball .628” 1.180” id 2.435” od output shaft (middle) 1 83-93 E3TZ-7025-A 6206N<br />
D75 Bearing, ball .590” 1.573” id 2.675” od front output shaft (front) 1 83-93 E3TZ-7025-C 6008-J<br />
E80 Bearing, ball .628” 1.180” id 2.435” od output shaft (rear) 1 83-93 E3TZ-7025-A 6206N<br />
E87 Bearing, caged (open) shift shaft 1 83-93 1300-127-002 TC1350-134<br />
E88 Bearing, caged (cup) output shaft (rear) 1 83-93 BHA-1612Z TC1350-136<br />
HARD PARTS<br />
A95 Housing, adapter BW1350 1 83-93 E8TZ-7050-F TC1350-170-R<br />
A96 Snap ring 41mm id input bearing in housing 1 83-93 E3TZ-7915-D TC1350-173-R<br />
A98 Snap ring 71mm id input bearing in housing 1 83-93 E3TZ-7915-C TC1350-172-R<br />
A99 Snap ring sun gear to planetary 1 83-93 E3RZ-7C122-A TC1350-175-R<br />
A100 Gear, sun BW1350 1 83-93 E3TZ-7D063-A TC1350-177-R<br />
A101 Planetary assembly (4 pinion gears) BW1350 1 83-91 E6TZ-7A398-A TC1350-180-R<br />
A101 Planetary assembly (6 pinion gears) BW1350 1 92-93 F1TZ-7A398-A TC1354-180-R<br />
A102 Shaft, front input BW1350 1 83-91 E3TZ-7017-D TC1350-182-R<br />
A102 Shaft, front input BW1350 1 92-93 F0TZ-7017-C TC1354-182-R<br />
A104 Hub, range BW1350 1 83-91 E3TZ-7100-E TC1350-183<br />
A104 Hub, range BW1350 1 92-93 F77Z-7100-AA TC1350-183A<br />
A105 Pin, pump drive BW1350 2 83-93 E0TZ-7A250-A TC1350-184<br />
A106 Shaft, rear output BW1350 1 83-90 E3TZ-7061-H TC1350-186-R<br />
A106 Shaft, rear output BW1350 1 91-93 1L5Z-7061-AA TC1350-186A-R<br />
A107 Spring, pump drive pin BW1350 1 83-93 E0TZ-7A205-A TC1350-185<br />
A111 Pump, oil assembly BW1350 1 83-93 AE TC1356-200<br />
A113 Retainer, oil pump BW1350 1 83-93 E3TZ-7E215-C TC1350-187<br />
A115 Clamp, oil pump hose BW1350 2 83-93 1345-056-005 TC1356-204<br />
B126 Sprocket, drive BW1350 1 83-93 F2TZ-7177-A TC1350-190<br />
B127 Collar, lock-up BW1350 1 83-93 E3TZ-7106-B TC1350-192<br />
B128 Spring, reduction BW1350 1 83-93 F1TZ-7289-D TC1350-193-R<br />
B129 Hub, reduction BW1350 1 83-93 E3TZ-7D164-B TC1350-195<br />
B130 Snap ring BW1350 1 83-93 E3TZ-7917-E TC1350-196-R<br />
B131 Hub, mode BW1350 1 83-93 E3TZ-7100-D TC1350-197<br />
B133 Snap ring BW1350 1 83-93 E3TZ-7917-A TC1350-198-R<br />
B136 Sleeve, speedo gear BW1350 1 83-93 n/a TC1350-199<br />
B140 Nut, rear output shaft BW1350 1 83-93 n/a TC1350-201-R<br />
BW1350<br />
© 2012 Autry Enterprises Ltd. 5
BW1350•1350<br />
BW1350<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
HARD PARTS (CONTINUED)<br />
C145 Collar, lock-up with electric shift 1 90-93 F1TZ-7106-B TC1354-192<br />
C146 Spring, reduction with electric shift 1 90-93 E6TZ-7D126+A TC1354-193<br />
C147 Hub, reduction with electric shift 1 90-93 E7TZ-7D164-A TC1354-202<br />
C148 Snap ring with electric shift 1 90-93 E3TZ-7917-E TC1350-196-R<br />
C149 Hub, mode with electric shift 1 90-93 E3TZ-7100-D TC1350-197<br />
C150 Housing, clutch coil with electric shift 1 90-93 F1TZ-7G362-A TC1354-203<br />
C152 Snap ring with electric shift 1 90-93 E3TZ-7917-A TC1350-198-R<br />
C154 Snap ring with electric shift 1 90-93 E3TZ-7917-A TC1350-198-R<br />
C160 Nut, rear output shaft with electric shift 1 90-93 n/a TC1350-201-R<br />
E190 Sprocket, driven BW1350 1 83-93 E3TZ-7A153-A TC1350-191<br />
E195 Housing, front case BW1350 1 83-93 E6TZ-7005-C TC1350-225-R<br />
E260 Shaft, shift with electric shift 1 91-93 1350-122-002 TC1354-206<br />
E261 Spacer, shaft shift with electric shift 1 91-93 1350-053-002 TC1354-207<br />
E262 Spring, shift cam with electric shift 1 91-93 1350-165-008 TC1354-208<br />
E263 Cam, shift with electric shift 1 91-93 1350-099-007 TC1354-209<br />
E280 Housing, rear case BW1350 1 83-93 F0TZ-7005-C TC1350-226-R<br />
TRANSFER CASE CHAINS<br />
B290 Chain, drive 62 links 1.250” wide (RP) BW1350 1 83-93 E3TZ-7A029-A HV-022<br />
ELECTRICAL COMPONENTS<br />
C295 Coil, magnetic clutch with electric shift 1 91-93 F57Z-7G361-B TC1354-260<br />
E296 Motor, shift (with 7 pins round plug) with electric shift 1 91-93 E8TZ-7G360-CA 600-800<br />
E297 Sensor, 4WD with electric shift 1 91-93 n/a TC1354-262<br />
E298 Sensor, speed (VSS) BW1350 1 91-93 E6TZ-7F293-A TC1354-265<br />
SHIFT FORKS AND PADS<br />
E300 Pad (nylon) range or reduction 2 83-93 1345-235-001 TC1345-28<br />
E302 Fork range or reduction 1 83-90 E6TZ-7289-A TC1350-123<br />
E302 Fork range or reduction 1 91-93 F2TZ-7289-A TC1354-123<br />
E305 Pad (nylon) mode or lock-up 2 83-93 1345-235-001 TC1345-28<br />
E307 Fork mode or lock-up 1 83-93 F1TZ-7289-D TC1350-124<br />
E315 Pad (nylon) range or reduction (with electric shift) 2 91-93 1345-235-001 TC1345-28<br />
E317 Fork range or reduction (with electric shift) 1 91-93 F2TZ-7289-A TC1354-123<br />
E320 Pad (nylon) mode or lock-up (with electric shift) 2 91-93 1345-235-001 TC1345-28<br />
E322 Fork mode or lock-up (with electric shift) 1 91-93 F1TZ-7289-D TC1350-124<br />
SPEEDO GEARS<br />
B330 Gear, speedo drive BW1350 1 83-93 F0TZ-17285-A TC1350-270-R<br />
NOTES<br />
6 © 2012 Autry Enterprises Ltd.
Tools<br />
<strong>Transfer</strong> <strong>Case</strong> Special Tools<br />
ADV-0156PAC<br />
ADV-0156SMAC<br />
ADV-M109-R<br />
PTO Bench Mount<br />
Tools<br />
NP236/242/262 seal installer<br />
ADV-T-271<br />
T-246-198<br />
NP271 Linkage Nut Remover<br />
NP246 Seal Installer<br />
J-45358<br />
J-29369-1<br />
J-29369-2<br />
<strong>Case</strong> Spreader<br />
Bearing Remover<br />
RN-0156<br />
PTO Bench Mount<br />
© 2012 Autry Enterprises Ltd. 7
BW1354•1354<br />
25<br />
96<br />
97<br />
98 55 56 99 58 100<br />
101<br />
102 60 45<br />
104<br />
108<br />
110<br />
115<br />
118<br />
BW1354<br />
A<br />
95<br />
vent<br />
bearing<br />
retainer<br />
sun<br />
gear<br />
planetary<br />
input<br />
shaft<br />
range<br />
slider<br />
late<br />
107<br />
106<br />
pump<br />
pins & spring<br />
output<br />
shaft pump<br />
rear<br />
3<br />
40<br />
119<br />
B<br />
290<br />
126 127<br />
filter<br />
128 129 130<br />
64<br />
66<br />
131<br />
133<br />
330 137<br />
134<br />
136 5 138<br />
speedo<br />
nut<br />
mode<br />
drive lock-up reduction<br />
hub gear yoke<br />
sprocket collar hub<br />
Manual Shift<br />
140<br />
drive chain<br />
141 142 143 145 150 295 156<br />
146 147 148 149 152 154 68 332 8 69 160<br />
C<br />
late<br />
pump<br />
lock-up<br />
collar<br />
reduction<br />
hub<br />
mode<br />
hub<br />
clutch<br />
housing<br />
magnetic<br />
clutch<br />
speedo<br />
gear<br />
yoke<br />
nut<br />
Electric Shift<br />
164 72 10<br />
165<br />
183<br />
166 167 168 170 180 181 75 182 184 185<br />
76 186<br />
D<br />
late<br />
yoke<br />
shield<br />
bolt on<br />
yoke<br />
u-joint<br />
output<br />
shaft<br />
front<br />
slip yoke<br />
output<br />
shaft<br />
front<br />
bearing<br />
retainer<br />
driven<br />
sprocket<br />
late<br />
late<br />
late<br />
late<br />
E<br />
190 195<br />
ring gear<br />
196<br />
28 192 80<br />
300 302<br />
202<br />
range<br />
fork<br />
203<br />
204<br />
305 307<br />
208<br />
mode<br />
fork<br />
217 218 220<br />
221<br />
216<br />
215<br />
209<br />
210<br />
roller<br />
211 212<br />
225 226<br />
shift rail<br />
detent<br />
spring<br />
12<br />
Manual Shift<br />
88<br />
280<br />
282<br />
283<br />
33<br />
297<br />
14<br />
4WD<br />
sensor<br />
front<br />
case half<br />
29<br />
315 317<br />
range<br />
fork<br />
242<br />
243<br />
244<br />
320 322<br />
247<br />
mode<br />
fork<br />
248<br />
249<br />
250 251<br />
shift rail<br />
rear<br />
case half<br />
260 261 262 263 87 30<br />
296<br />
15<br />
298<br />
speed<br />
sensor<br />
late<br />
late<br />
Electric Shift<br />
shift<br />
shaft<br />
torsion<br />
spring<br />
shift<br />
cam<br />
electric<br />
shift motor<br />
BW1354<br />
TC1354<br />
8 © 2012 Autry Enterprises Ltd.
BW1354•1354<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
K37 Kit, bearing/gasket/seal BW1354 1 91-04 n/a TK-1354<br />
K37 Kit, gasket/seal BW1354 1 91-04 n/a K105-926<br />
GASKETS AND RUBBER COMPONENTS<br />
A3 Hose, oil pump BW1354 1 91-04 E0TZ-7A098-AA TC1356-203<br />
n/i Gasket, adapter adapter housing to transfer case 1 91-04 M353317A 13594<br />
METAL CLAD SEALS<br />
A25 Seal, metal clad front output shaft 1 91-04 F3TZ-7B215-A 205-16043<br />
E28 Seal, metal clad rear output shaft 1 91-04 F3TZ-7B215-A 205-16043<br />
E33 Seal, metal clad front input shaft 1 91-04 F3TZ-7B215-A 205-16043<br />
FILTERS<br />
A40 Filter, oil pump BW1354 1 91-04 E0TZ-7A098-AA TC1356-050<br />
BUSHINGS<br />
A45 Bushing front input shaft (rear) 1 91-04 n/a TC1350-159<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A55 Bearing, ball .628” 1.773” id 2.950” od front input shaft 1 91-04 E3TZ-7025-B 6009N<br />
A60 Bearing, caged (cup) front input shaft (middle) 1 91-04 BCE-1816 TC1350-135<br />
C68 Bearing, ball .628” 1.180” id 2.435” od front output shaft (rear) 1 91-04 E3TZ-7025-A 6206N<br />
D75 Bearing, ball .590” 1.573” id 2.675” od front output shaft (front) 1 91-04 E3TZ-7025-C 6008-J<br />
E80 Bearing, ball .628” 1.180” id 2.435” od front output shaft (middle) 1 91-04 E3TZ-7025-A 6206N<br />
E88 Bearing, caged (cup) front output shaft (rear) 1 91-04 BHA-1612Z TC1350-136<br />
HARD PARTS<br />
A96 Housing, adapter BW1354 1 91-04 F0TZ-7050-B TC1354-170<br />
A97 Snap ring 71mm id BW1354 1 91-04 E3TZ-7915-C TC1350-172-R<br />
A98 Snap ring 41mm id BW1354 1 91-04 E3TZ-7915-D TC1350-173-R<br />
A99 Snap ring BW1354 1 91-04 E3RZ-7C122-A TC1350-175-R<br />
A100 Gear, sun BW1354 1 91-04 E3TZ-7D063-A TC1350-177-R<br />
A101 Planetary assembly (6 pinion gears) BW1354 1 91-04 F1TZ-7A398-A TC1354-180-R<br />
A102 Shaft, front input BW1354 1 91-04 F0TZ-7017-C TC1354-182-R<br />
A104 Hub, range BW1354 1 91-04 F77Z-7100-AA TC1350-183A<br />
A106 Pin, pump drive BW1354 2 91-04 E0TZ-7A250-A TC1350-184<br />
A107 Spring, pump drive pin BW1354 1 91-04 E0TZ-7A205-A TC1350-185<br />
A110 Shaft, rear output BW1354 1 91-04 E3TZ-7061-H TC1350-186-R<br />
A110 Shaft, rear output BW1354 1 91-04 1L5Z-7061-AA TC1350-186A-R<br />
A115 Pump, oil assembly BW1354 1 91-04 AE TC1356-200<br />
A118 Retainer, oil pump BW1354 1 91-04 E3TZ-7E215-C TC1350-187<br />
A119 Clamp, oil pump hose BW1354 2 91-04 1345-056-005 TC1356-204<br />
B126 Sprocket, drive BW1354 1 91-04 F2TZ-7177-A TC1350-190<br />
B127 Collar, lock-up BW1354 1 91-93 F1TZ-7106-B TC1354-192<br />
B128 Spring, reduction BW1354 1 91-04 F1TZ-7289-D TC1350-193-R<br />
B129 Hub, reduction BW1354 1 91-04 E3TZ-7D164-B TC1350-195<br />
B130 Snap ring BW1354 1 91-04 E3TZ-7917-E TC1350-196-R<br />
B131 Hub, mode BW1354 1 91-04 E3TZ-7100-D TC1350-197<br />
B133 Snap ring BW1354 1 91-04 E3TZ-7917-A TC1350-198-R<br />
B136 Sleeve, speedo gear BW1354 1 91-04 n/a TC1350-199<br />
B138 Nut, rear output shaft BW1354 1 91-04 E3TZ-7045-C TC1350-201-R<br />
C145 Collar, lock-up with electric shift 1 91-93 F1TZ-7106-B TC1354-192<br />
C146 Spring, reduction with electric shift 1 91-04 E6TZ-7D126-A TC1354-193<br />
C147 Hub, reduction with electric shift 1 91-04 E7TZ-7D164-A TC1354-202<br />
C148 Snap ring with electric shift 1 91-93 E3TZ-7917-E TC1350-196-R<br />
C149 Hub, mode with electric shift 1 91-04 E3TZ-7100-D TC1350-197<br />
C150 Housing, clutch coil with electric shift 1 91-04 F1TZ-7G362-A TC1354-203<br />
C152 Snap ring with electric shift 1 91-04 E3TZ-7917-A TC1350-198-R<br />
C154 Snap ring with electric shift 1 91-04 E3TZ-7917-A TC1350-198-R<br />
BW1354<br />
© 2012 Autry Enterprises Ltd. 9
BW1354•1354<br />
BW1354<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
HARD PARTS (CONTINUED)<br />
C160 Nut, rear output shaft with electric shift 1 91-04 E3TZ-7045-C TC1350-201-R<br />
D185 Sprocket, driven BW1354 1 91-04 1L5Z-7177-AA TC1354-191<br />
E195 Housing, front case BW1354 1 91-04 F0TZ-7005-E TC1354-225-R<br />
E260 Shaft, shift with electric shift 1 91-04 1350-053-002 TC1354-206<br />
E261 Spacer, shaft shift with electric shift 1 91-04 1350-053-002 TC1354-207<br />
E262 Spring, shift cam with electric shift 1 91-04 1350-165-008 TC1354-208<br />
E263 Cam, shift with electric shift 1 91-04 1350-099-007 TC1354-209<br />
E280 Housing, rear case BW1354 1 91-04 1L5Z-7005-AA TC1354-226-R<br />
E280 Housing, rear case BW1354 1 91-04 F87Z-7005-CA TC1354-227-R<br />
TRANSFER CASE CHAINS<br />
B290 Chain, drive 62 links 1.250” wide (RP) BW1354 1 91-98 1L2Z-7A029-AA HV-022<br />
B290 Chain, drive 62 links 1.250” wide (RP) Sport Trac/Explorer Sport 1 00-04 1L5Z-7A092-AA HV-068<br />
B290 Chain, drive 62 links 1” wide (RP) Sport Trac/Explorer Sport 1 05-06 n/a HV-505<br />
ELECTRICAL COMPONENTS<br />
C295 Coil, magnetic clutch with electric shift 1 91-04 F57Z-7G361-B TC1354-260<br />
E296 Motor, shift (with 7 pins round plug) with electric shift 1 91-95 F57Z-7G361-B 600-800<br />
E296 Motor, shift (with 7 pins round plug) with electric shift 1 95-04 1L5Z-7G360-CB 600-807<br />
E297 Sensor, 4WD with electric shift 1 91-04 n/a TC1354-262<br />
E298 Sensor, speed (VSS) BW1354 2 91-04 E6TZ-7F293-A TC1354-265<br />
SHIFT FORKS AND PADS<br />
E300 Pad (nylon) range or reduction 2 91-04 1345-235-001 TC1345-28<br />
E302 Fork range or reduction 1 91-04 E6TZ-7289-A TC1350-123<br />
E302 Fork range or reduction 1 91-04 F2TZ-7289-A TC1354-123<br />
E305 Pad (nylon) mode or lock-up 1 91-04 1345-235-001 TC1345-28<br />
E307 Fork mode or lock-up 1 91-04 F1TZ-7289-D TC1350-124<br />
E315 Pad (nylon) range or reduction (with electric shift) 2 91-04 1345-235-001 TC1345-28<br />
E317 Fork range or reduction (with electric shift) 1 91-04 F2TZ-7289-A TC1354-123<br />
E320 Pad (nylon) mode or lock-up (with electric shift) 2 91-04 1345-235-001 TC1345-28<br />
E322 Fork mode or lock-up (with electric shift) 1 91-04 F1TZ-7289-D TC1350-124<br />
SPEEDO GEARS<br />
B330 Gear, speedo drive BW1354 1 91-04 1350-110-002 TC1350-270-R<br />
NOTES<br />
10 © 2012 Autry Enterprises Ltd.
Fixes<br />
<strong>Transfer</strong> <strong>Case</strong> Special Fixes<br />
Fixes<br />
36605-01<br />
transfer case saver (bag of 5)<br />
BW1356<br />
100240-01K<br />
split ring retainer<br />
foe NP230 series<br />
100246-01<br />
anti-ware transfer case saver<br />
NP240/136<br />
100246-02K<br />
transfer case pump plate<br />
for NP136/149/236/246/261/263<br />
100420-02K<br />
split ring retainer<br />
foe NP240 series<br />
BRNY<br />
case repair plate<br />
foe NP136/23/246<br />
K068<br />
rear output bearing retainer (bag of 3)<br />
for Np230 series<br />
TC-4405C<br />
casse repair insert<br />
for BW4405<br />
K067<br />
rear output bearing retainer (bag of 3)<br />
for Np240 series<br />
© 2012 Autry Enterprises Ltd. 11
BW1356•1356<br />
100<br />
60<br />
101<br />
102<br />
110<br />
112<br />
64 45<br />
113<br />
114<br />
115<br />
122<br />
126<br />
BW1356<br />
A<br />
PTO<br />
drive<br />
gear<br />
planetary<br />
w/input gear<br />
range<br />
slider<br />
116<br />
117<br />
pump<br />
pins & spring<br />
output<br />
shaft<br />
rear<br />
pump<br />
3<br />
40<br />
124<br />
125<br />
B<br />
270<br />
130<br />
drive<br />
sprocket<br />
drive chain<br />
132<br />
134 135 136<br />
68<br />
133<br />
137 138 139 330 5 141 6<br />
70<br />
144<br />
mode<br />
speedo<br />
nut<br />
lock-up reduction<br />
hub hub<br />
gear yoke<br />
collar<br />
Manual Shift<br />
150<br />
159<br />
155 156 157 280 72<br />
166<br />
158 160 163 164 332<br />
filter<br />
8<br />
74<br />
170<br />
C<br />
lock-up<br />
collar<br />
reduction<br />
hub<br />
mode<br />
hub clutch<br />
housing<br />
magnetic<br />
clutch<br />
yoke<br />
nut<br />
Electric Shift<br />
D<br />
175 76<br />
10<br />
176 177 80 178<br />
nut<br />
yoke<br />
179<br />
output<br />
shaft<br />
front<br />
180<br />
81 182<br />
driven<br />
sprocket<br />
192<br />
E<br />
190<br />
25<br />
26<br />
14<br />
195<br />
front<br />
case half<br />
196 197<br />
ring gear<br />
199<br />
300 302 305 307<br />
202 mode<br />
fork 209 210 252<br />
203<br />
range 204 208<br />
254<br />
shift rail<br />
56<br />
30<br />
fork<br />
211<br />
212 213 215<br />
216<br />
15<br />
214 detent roller 89 260 281 18<br />
spring<br />
Manual Shift<br />
4WD<br />
sensor<br />
rear<br />
245 246<br />
247 248 87 28 case half<br />
19 284<br />
282<br />
shift<br />
shift<br />
shaft<br />
torsion<br />
spring cam<br />
Electric Shift<br />
electric<br />
shift motor<br />
speed<br />
sensor<br />
BW1356<br />
TC1356<br />
12 © 2012 Autry Enterprises Ltd.
BW1356•1356<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal BW1356 1 87-97 AE TK-1356<br />
n/i Kit, gasket/seal BW1356 1 87-97 AE K105-931<br />
GASKETS AND RUBBER COMPONENTS<br />
A3 Hose, oil pump BW1356 1 87-97 n/a TC1356-203<br />
n/i Gasket, adapter housing BW1356 1 87-97 04130678 13591<br />
METAL CLAD SEALS<br />
E25 Seal, metal clad front input 1 87-97 F4TZ-7B215-A 205-18994<br />
E26 Seal, metal clad front output 1 87-97 F4TZ-7B215-A 205-18994<br />
E26 Seal, metal clad front output 1 94-97 E5TZ-7B215-A 205-18892<br />
E30 Seal, metal clad rear output 1 87-97 F4TZ-7B215-B 205-18507<br />
E30 Seal, metal clad rear output (Bronco) 1 94-97 F4TZ-7B215-A 205-18994<br />
FILTERS<br />
A40 Filter, oil pump BW1356 1 87-97 E0TZ-7A098-AA TC1356-050<br />
BUSHINGS<br />
A45 Bushing rear output shaft (front) 1 87-97 n/a TC1356-165<br />
E56 Bushing extension housing 1 87-97 TC1356-62 TC1356-162<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A60 Bearing, ball .628” 3.148” od 1.970” id front input 1 87-97 E7TZ-7025-A 6010N<br />
A64 Bearing, caged (open) front input shaft 1 87-97 B-2012 TC1356-135<br />
B68 Bearing, ball .671” 1.377” id 2.837” od rear output (rear)(manual shift) 1 87-97 F0TZ-7025-B 6207N<br />
C72 Bearing, ball .671” 1.377” id 2.837” od rear output (rear)(electric shift) 1 87-97 F0TZ-7025-B 6207N<br />
D80 Bearing, ball .671” 1.377” id 2.837” od front output (front) 1 87-97 C8TZ-7025-C 6207N<br />
E89 Bearing, caged (cup) front output shaft (rear) 1 87-97 BK-3026 TC1356-143<br />
HARD PARTS<br />
A110 Planetary kit planet/ring gear/range hub 1 87-97 F5TZ-7D323-BB TC1356-250<br />
A112 Hub, range shift (38T) BW1356 1 87-96 E7TZ-7100-A TC1356-120<br />
A112 Hub, range shift (31T) BW1356 1 97-97 F5TZ-7100-C TC1356-121<br />
A114 Shaft, rear output w/slip yoke 1 87-97 E7TZ-7061-B TC1356-192<br />
A122 Pump, oil assembly BW1356 1 87-97 n/a TC1356-200<br />
A124 Clamp, oil pump hose BW1356 1 87-97 n/a TC1356-204<br />
A125 Clamp, oil pump hose BW1356 1 87-97 n/a TC1356-204<br />
A126 Retainer, oil pump BW1356 1 87-97 E7TZ-7E215-A TC1356-206<br />
B130 Gear, drive sprocket BW1356 1 87-97 E7TZ-7177-B TC1356-152<br />
D180 Gear, driven sprocket BW1356 1 87-97 1356-144-002 TC1356-185<br />
E245 Shaft, shift BW1356 electric shift 1 87-97 1356-122-007 TC1356-209<br />
E247 Spring, torsion BW1356 1 87-91 n/a TC1356-207<br />
E248 Cam, electric shift BW1356 1 91-97 n/a TC1356-208<br />
E252 <strong>Case</strong>, rear manual shift 1 87-97 E7TZ-7005-C TC1356-101<br />
TRANSFER CASE CHAINS<br />
B270 Chain, drive 84 links 1.250” wide (RP) BW1356 1 87-97 E2TZ-7A029-A HV-012<br />
ELECTRICAL COMPONENTS<br />
E282 Motor, electric shift round connector 7 pins 1 87-90 E8TZ-7G360-B 600-804<br />
E282 Motor, electric shift round connector 7 pins 1 91-97 F1TZ-7G360-C 600-801<br />
SHIFT FORKS AND PADS<br />
E300 Pad, shift fork (nylon) range 2 87-97 E9TZ-7C430-A TC1356-28<br />
E302 Fork range 1 87-97 F1TZ-7289-A TC1356-123<br />
E305 Pad (nylon) mode 3 87-97 1345-235-001 TC1345-28<br />
E307 Fork mode 1 87-97 4400-596-002 TC1356-124<br />
SPEEDO GEARS<br />
C332 Gear, speedo (yellow) w/o steel sleeve 1 87-97 n/a 02-326<br />
NOTES<br />
BW1356<br />
© 2012 Autry Enterprises Ltd. 13
BW1359•1359<br />
25<br />
70<br />
71<br />
45 72 47<br />
74<br />
75<br />
48 49<br />
40<br />
76<br />
A<br />
input<br />
shaft<br />
spacer<br />
range<br />
slider<br />
output<br />
shaft<br />
rear<br />
BW1359<br />
bearing<br />
retainer<br />
80 81 53 100 83<br />
84<br />
5<br />
56<br />
85<br />
B<br />
range<br />
hub<br />
speedo<br />
gear<br />
yoke<br />
nut<br />
90<br />
95<br />
30<br />
C<br />
28<br />
output plug<br />
solid<br />
front<br />
case half<br />
rear<br />
case half<br />
BW1359<br />
TC1359<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal BW1359 1 84-90 TCRK-1359 TK-1359<br />
n/i Kit, gasket/seal BW1359 1 84-90 DTK-1359 K105-947<br />
GASKETS AND RUBBER COMPONENTS<br />
n/i Gasket, adapter adapter housing to transfer case 1 87-89 M353317A 13594<br />
METAL CLAD SEALS<br />
A25 Seal, metal clad front input shaft 1 87-89 E3TZ-7B215-F 205-17502<br />
C30 Seal, metal clad rear output shaft 1 87-89 F3TZ-7B215-A 205-16043<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A45 Bearing, ball .628” 1.773” id 2.950” od front input sahft 1 84-90 E7TZ-7025-B 6009N<br />
B53 Bearing, ball .628” 1.180” id 2.435” od rear output shaft 1 84-90 E7TZ-7025-C 6206N<br />
NOTES<br />
14 © 2012 Autry Enterprises Ltd.
BW4403•4403<br />
175 100 45<br />
103 105 108 110 112 65 114 117118<br />
120<br />
121<br />
48 123 124 69 190<br />
126<br />
10 71 129<br />
A<br />
drive<br />
sprocket<br />
spring<br />
roller<br />
input/output<br />
shaft<br />
latch<br />
plate<br />
friction<br />
gear<br />
speedo<br />
drive<br />
yoke<br />
gear<br />
nut<br />
BW4403<br />
drive chain<br />
135 136 75 138<br />
140<br />
78<br />
B<br />
front<br />
output shaft<br />
shield<br />
driven<br />
sprocket<br />
30<br />
150<br />
55<br />
156<br />
160<br />
34<br />
153<br />
C<br />
32<br />
drive chain<br />
damper/guide<br />
front<br />
case half<br />
rear<br />
case half<br />
BW4403<br />
TC4403<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal BW4403 1 99-01 AE TK-4403<br />
n/i Kit, gasket/seal BW4403 1 99-01 AE K105-944<br />
GASKETS AND RUBBER COMPONENTS<br />
n/i Gasket, adapter BW4403 1 99-01 M353317A 13594<br />
METAL CLAD SEALS<br />
C30 Seal, metal clad input shaft 1 99-01 XL2Z-7B215-AA 205-18662<br />
C32 Seal, metal clad front output shaft 1 99-01 F3TZ-7B215-A 205-16043<br />
C34 Seal, metal clad rear output shaft 1 99-01 F3TZ-7B215-A 205-16043<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A65 Bearing, ball .628” 1.773” id 2.950” od input/output shaft (front) 1 99-01 XL2Z-7025-AA 6009N<br />
A69 Bearing, ball .628” 1.180” id 2.435” od input/output shaft (rear) 1 99-01 E3TZ-7025-A 6206N<br />
B75 Bearing, ball .628” 1.180” id 2.435” od front output shaft (front) 1 99-01 E3TZ-7025-A 6206N<br />
B78 Bearing, ball .628” 1.773” id 2.950” od front output shaft (rear) 1 99-01 XL2Z-7025-AA 6009N<br />
TRANSFER CASE CHAINS<br />
A175 Chain, drive 74 links 1.250” wide (RJ) BW4403 1 99-01 XL2Z-7A029-AA HV-051<br />
NOTES<br />
© 2012 Autry Enterprises Ltd. 15
BW4404•4404<br />
175<br />
105<br />
108<br />
100 65<br />
103<br />
110<br />
69<br />
45<br />
112<br />
114 117 118 123<br />
190 126<br />
71<br />
74<br />
72<br />
124 75<br />
76<br />
10 129<br />
BW4404<br />
A<br />
input<br />
shaft<br />
drive<br />
sprocket<br />
drive chain<br />
viscous<br />
coupling<br />
sun<br />
gear<br />
planetary<br />
ring<br />
gear<br />
rear<br />
output<br />
shaft<br />
speedo<br />
drive<br />
gear<br />
135<br />
136 79<br />
138 140 82<br />
B<br />
front<br />
output shaft<br />
shield<br />
driven<br />
sprocket<br />
30<br />
150<br />
55<br />
153<br />
156<br />
160<br />
34<br />
C<br />
32<br />
drive chain<br />
damper/guide<br />
front<br />
case half<br />
rear<br />
case half<br />
BW4404<br />
TC4404<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal BW4404 1 96-03 AE TK-4404<br />
n/i Kit, gasket/seal BW4404 1 96-03 AE K105-929<br />
GASKETS AND RUBBER COMPONENTS<br />
n/i Gasket, adapter housing adapter housing to transfer case 1 96-03 04130678 13591<br />
METAL CLAD SEALS<br />
C30 Seal, metal clad input shaft 1 96-03 F4TZ-7B215-A 205-18771<br />
C32 Seal, metal clad front output shaft 1 96-03 F3TZ-7B215-A 205-16043<br />
C34 Seal, metal clad rear output shaft 1 96-03 F3TZ-7B215-A 205-16043<br />
BUSHINGS<br />
C55 Bushing front case to input 1 96-03 F67Z-7Z227-AA TC4404-165<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A65 Bearing, ball .628” 1.773” id 2.950” od front input shaft 1 96-03 XL2Z-7025-AA 6009N<br />
A72 Bearing, cage .624” .823” id 1.132” od rear output (inner) 1 96-03 SCH1310 JH1310<br />
A74 Bearing, ball .708” 1.565” id 3.148” od rear output shaft (front) 1 96-03 F5TZ-7025-C 6208N<br />
A75 Bearing, ball .352” 1.174” id 2.166” od rear output shaft (rear) 1 96-03 16006 16006<br />
A75 Bearing, ball .510” 1.174” id 2.166” od rear output shaft (rear) 1 96-03 6006 6006<br />
B79 Bearing, ball .671” 1.377” id 2.837” od front output shaft (front) 1 96-03 C8TZ-7025-C 6207N<br />
B82 Bearing, ball .628” 1.180” id 2.435” od front output shaft (rear) 1 96-03 E7TZ-7025-C 6206N<br />
HARD PARTS<br />
A100 Gear, input shaft BW4404 1 96-03 F67Z-7017-AA TC4404-150<br />
A105 Gear, drive sprocket BW4404 1 96-03 4404-144-001 TC4404-175-R<br />
A108 Clutch, viscous assembly BW4404 1 96-03 4404-625-001 TC4404-178<br />
A110 Gear, planetary sun BW4404 1 96-03 4404-665-001 TC4404-180-R<br />
A112 Gear, planetary BW4404 1 96-03 4472-659-003 TC4404-182-R<br />
16 © 2012 Autry Enterprises Ltd.
BW4404•4404<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
HARD PARTS (CONTINUED)<br />
A114 Gear, planetary ring BW4404 1 96-03 1372-162-001 TC4404-184-R<br />
A117 Shaft, rear output BW4404 (narrow bearing) 1 96-03 4404-171-002 TC4404-186-R<br />
A117 Shaft, rear output BW4404 (wide bearing) 1 96-03 4404-171-003 TC4404-187-R<br />
B140 Gear, driven sprocket BW4404 1 96-03 4404-144-002 TC4404-195-R<br />
C150 Housing, front case BW4404 (id tag 001/005) 1 96-03 4404-539-001 TC4404-205-R<br />
C150 Housing, front case BW4404 (id tag 006) 1 96-03 4404-539-003 TC4404-206-R<br />
C160 Housing, rear case BW4404 (id tag 001/002/003) 1 96-03 4404-456-001 TC4404-210-R<br />
C160 Housing, rear case BW4404 (id tag 004) 1 96-03 4404-456-002 TC4404-211-R<br />
C160 Housing, rear case BW4404 (id tag 005/007) 1 96-03 4404-456-003 TC4404-212-R<br />
TRANSFER CASE CHAINS<br />
A175 Chain, drive 74 links 1.250” wide (RJ) BW4404 1 96-03 XL2Z-7A029-AA HV-051<br />
A175 Chain, drive 74 links 1.250” wide (RJ) 2 blue links (w/5.0L V/8) 1 96-03 F87Z-7A029-BB HV-070<br />
NOTES<br />
BW4404<br />
© 2012 Autry Enterprises Ltd. 17
BW4405•4405<br />
BW4405<br />
A<br />
B<br />
150<br />
drive chain<br />
80 50 51<br />
drive<br />
sprocket<br />
81 53 40<br />
input<br />
shaft<br />
56 100 101<br />
clutch<br />
housing<br />
30 31 83 54 84<br />
clutch pack<br />
85<br />
sun<br />
gear planetary<br />
86 88<br />
58 102 103 105<br />
54 106 107 155<br />
plate<br />
range<br />
slider<br />
output<br />
shaft<br />
rear<br />
spring<br />
cam<br />
magnetic<br />
apply<br />
magnetic<br />
plate<br />
clutch clutch<br />
coil coil<br />
housing<br />
3<br />
90<br />
91 92 93<br />
filter<br />
pump<br />
94<br />
35<br />
59 110 60 210 112<br />
113<br />
reluctor<br />
wheel<br />
yoke<br />
5 61 114<br />
nut<br />
116 63 7 117 118 64<br />
119<br />
120 212<br />
65<br />
C<br />
nut<br />
yoke<br />
shield<br />
output<br />
shaft<br />
front<br />
driven<br />
sprocket<br />
reluctor<br />
wheel<br />
20<br />
126<br />
127 128<br />
140<br />
24<br />
10<br />
160<br />
D<br />
125<br />
ring gear<br />
vent<br />
21 130<br />
front<br />
case half<br />
magnet<br />
190 192<br />
range<br />
fork<br />
141<br />
133<br />
142 11 161 163<br />
shift rail<br />
lower<br />
135 136 137 138 rear<br />
speed<br />
case half sensor electric<br />
shift motor<br />
shift<br />
shaft<br />
torsion<br />
spring<br />
shift<br />
cam<br />
upper<br />
speed<br />
sensor<br />
BW4405<br />
TC4405<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal BW4405 1 95-01 AE TK-4405<br />
n/i Kit, gasket/seal BW4405 1 95-01 AE K105-938<br />
GASKETS AND RUBBER COMPONENTS<br />
n/i Gasket, adapter adapter housing to transfer case 1 95-06 M353317A 13594<br />
METAL CLAD SEALS<br />
D20 Seal, metal clad front input shaft 1 95-01 F3TZ-7B215-A 205-16043<br />
D21 Seal, metal clad front output shaft 1 95-01 F3TZ-7B215-A 205-16043<br />
D24 Seal, metal clad rear output shaft 1 95-01 F3TZ-7B215-A 205-16043<br />
CLUTCH PLATES<br />
B30 Friction .078” 4.727” id 31T external teeth 6 95-01 138731-195 TC4405-103<br />
B31 Friction .078” 5.590” od 19T internal teeth 5 95-01 138730-195 TC4405-104<br />
18 © 2012 Autry Enterprises Ltd.
BW4405•4405<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
FILTERS<br />
A35 Filter BW4405 1 95-01 4400-238-002 TC4405-050<br />
BUSHINGS<br />
A40 Bushing input shaft (inner) 1 95-01 1345-127-002 TC4405-165<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A50 Bearing, ball .747” 3.344” od 1.772” id front input shaft 1 95-01 F57Z-7127-A 6209N<br />
A53 Bearing, caged (cup) front input shaft (inner) 1 95-01 BCE-1816 TC1350-135<br />
B60 Bearing, ball .746” 2.832” od 1.180” id output shaft (rear) 1 95-01 F0TZ-7025-B 6306N<br />
C64 Bearing, ball .746” 2.832” od 1.180” id front output shaft (front) 1 95-01 F0TZ-7025-B 6306N<br />
C65 Bearing, ball .628” 1.180” id 2.435” od front output shaft (rear) 1 95-01 F57Z-7025-A 6206N<br />
HARD PARTS<br />
A81 Gear, input shaft BW4405 1 95-01 F57Z-7017-A TC4405-150<br />
A84 Gear, sun BW4405 1 95-01 E3TZ-7D063-A TC1350-177-R<br />
A85 Planetary assembly (6 pinion gears) BW4405 1 95-01 F1TZ-7A398-A TC1354-180-R<br />
A86 Hub, range BW4405 1 95-01 F77Z-7100-AA TC1350-183A<br />
A88 Shaft, rear output BW4405 1 95-01 AE TC4405-190-R<br />
A90 Pump assembly BW4405 1 95-01 AE TC4405-200-R<br />
B100 Gear, drive sprocket BW4405 (1.250” wide chain) 1 95-97 4405-644-001 TC4405-195<br />
B100 Gear, drive sprocket BW4405 (1” wide chain) 1 97-01 4405-644-002 TC4405-196<br />
B107 Housing, magnetic clutch BW4405 1 95-01 4405-212-902 TC4405-175-R<br />
C119 Shaft, front output BW4405 1 95-01 AE TC4405-215-R<br />
C120 Gear, driven sprocket BW4405 (1.250” wide chain) 1 95-97 4405-144-006 TC4405-220<br />
C120 Gear, driven sprocket BW4405 (1” wide chain) 1 97-01 4405-144-008 TC4405-221<br />
D126 Housing, front case BW4405 1 95-01 AE TC4405-223-R<br />
D135 Shaft, shift BW4405 1 95-01 1350-053-002 TC1354-206<br />
D137 Spring, shift cam BW4405 1 95-01 1350-165-008 TC1354-208<br />
D138 Cam, shift BW4405 1 95-01 4405-099-009 TC4405-099<br />
D140 Housing, rear case BW4405 (manual shift) 1 95-01 4405-539-004 TC4405-225<br />
D140 Housing, rear case BW4405 (electric shift) 1 95-01 4405-539-007 TC4405-226<br />
n/i Guide, roller (shift fork repair) BW4405 (Sonnax) 1 95-01 100329-01K SON-100329-01K<br />
n/i Tab, pump stop repair BW4405 (Sonnax) 1 95-01 100912-01K SON-100912-01K<br />
n/i Tab, pump stop repair BW4405 (Adapt-a-case) 1 95-01 TC4405C ADV-TC4405C<br />
TRANSFER CASE CHAINS<br />
B150 Chain, drive 74 links 1.250” wide (RJ) BW4405 1 95-97 XL2Z-7A029-AA HV-051<br />
B150 Chain, drive 74 links 1” wide (RJ) BW4405 1 97-01 XL2Z-7A029-BB HV-067<br />
ELECTRICAL COMPONENTS<br />
B155 Coil, magnetic clutch BW4411 1 95-01 4400-015-020 TC4405-180<br />
D163 Motor, electric shaft BW4405 (7-pin rectangular connector) 1 95-01 XL2Z-7G360-AA 600-803<br />
SHIFT FORKS AND PADS<br />
D190 Pad, shift fork (nylon) range 2 95-06 E9TZ-7C430-A TC1356-28<br />
D192 Fork, range casting #4405-096-903 1 95-06 F57Z-7289-A TC4405-123<br />
NOTES<br />
BW4405<br />
© 2012 Autry Enterprises Ltd. 19
BW4406•4406<br />
BW4406<br />
A<br />
105<br />
85 86<br />
55 90<br />
57 40<br />
91<br />
planetary<br />
w/input<br />
shaft/gear<br />
range<br />
slider<br />
output<br />
shaft<br />
rear<br />
165 106 107 108 109 110 113<br />
111 114 170 60 210 115<br />
92<br />
3<br />
99<br />
95<br />
96 97 98<br />
filter<br />
100<br />
pump<br />
35<br />
B<br />
drive<br />
sprocket<br />
drive chain<br />
lock-up<br />
collar<br />
spring mode spring<br />
hub plate<br />
Manual/Electric Shift<br />
magnetic<br />
clutch<br />
coil<br />
housing<br />
magnetic<br />
clutch<br />
coil<br />
reluctor<br />
wheel<br />
C<br />
118 119 62 63 64 120 122<br />
30 31<br />
mode<br />
hub<br />
lock-up<br />
collar<br />
drive<br />
sprocket<br />
clutch<br />
housing<br />
clutch pack<br />
123 65 125 126 127 128 129 171<br />
spring<br />
plate cam<br />
magnetic magnetic<br />
apply<br />
clutch clutch<br />
plate<br />
coil coil<br />
housing<br />
Torque On Demand (TOD)<br />
67 68 69 131 70 132<br />
212<br />
reluctor<br />
wheel<br />
135 136 72 137<br />
138 214 73<br />
D<br />
output<br />
shaft<br />
front<br />
shield<br />
driven<br />
sprocket<br />
reluctor<br />
wheel<br />
(TOD)<br />
E<br />
21<br />
173<br />
4WD<br />
sensor<br />
22<br />
140 141 143<br />
front<br />
case half<br />
ring gear<br />
145 146<br />
roller<br />
147<br />
23<br />
detent<br />
spring<br />
148<br />
Manual Shift<br />
190<br />
45 46<br />
range<br />
fork<br />
192 195<br />
153 154<br />
mode<br />
fork<br />
shift rail<br />
158<br />
156<br />
shift cam rear<br />
w/torsion spring case half<br />
Electric/TOD Shift<br />
175<br />
speed<br />
sensor<br />
(TOD)<br />
10 176<br />
extension<br />
housing<br />
upper<br />
speed sensor<br />
(TOD)<br />
11 177<br />
lower<br />
speed sensor<br />
(TOD)<br />
160<br />
49 24<br />
178<br />
electric<br />
shift motor<br />
Electric/TOD Shift<br />
BW4406<br />
TC4406<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal BW4406 1 97-04 AE TK-4406<br />
n/i Kit, gasket/seal BW4406 1 97-04 AE K105-923<br />
GASKETS AND RUBBER COMPONENTS<br />
n/i Gasket, adapter housing BW4406 1 97-04 04130678 13591<br />
20 © 2012 Autry Enterprises Ltd.
BW4406•4406<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
METAL CLAD SEALS<br />
E21 Seal, metal clad input shaft 1 97-04 F77Z-7B215-AA 205-18771<br />
E22 Seal, metal clad front output shaft 1 97-04 F4TZ-7B215-A 205-18994<br />
E24 Seal, metal clad rear output shaft 1 97-04 F4TZ-7B215-B 205-18507<br />
CLUTCH PLATES<br />
C30 Friction .065” 4.727” id 31T external teeth (TOD) 7 97-04 APC-138731 TC4406-103<br />
C31 Friction .065” 5.590” id 19T internal teeth (TOD) 6 97-04 APC-138730 TC4406-104<br />
FILTERS<br />
A35 Filter, oil BW4406 1 97-04 4400-238-003 TC4406-050<br />
BUSHINGS<br />
A40 Bushing input shaft (inner) 1 97-04 n/a TC4406-165<br />
E49 Bushing extension housing 1 97-04 TC1356-62 TC1356-162<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A55 Bearing, ball .830” 3.935” od 2.165” id front input shaft 1 97-04 F5TZ-7025-B 6211L<br />
A57 Bearing, caged (cup) front input shaft (inner) 1 97-04 BK-3026 TC4406-135<br />
B60 Bearing, ball .671” 1.377” id 2.837” od rear output shaft (manual/electric shift) 1 97-04 F0TZ-7005-A 6207N<br />
C70 Bearing, ball .671” 1.377” id 2.837” od rear output shaft (TOD) 1 97-04 F0TZ-7005-A 6207N<br />
D72 Bearing, ball .708” 1.565” id 3.148” od front output shaft (front) 1 97-04 F5TZ-7025-C 6208N<br />
D73 Bearing, ball .671” 1.377” id 2.837” od front output shaft (rear) 1 97-04 F0TZ-7005-A 6207N<br />
HARD PARTS<br />
A90 Gear, planetary w/input BW4406 (manual/electric shift) 1 97-04 4406-659-003 TC4406-175-R<br />
A90 Gear, planetary w/input BW4406 (w/torque on demand) 1 97-04 4406-659-002 TC4406-176-R<br />
A91 Hub, range slider BW4406 1 97-04 4407-089-003 TC4406-179-R<br />
A92 Shaft, rear output BW4406 1 97-04 AE TC4406-190-R<br />
A95 Pump, oil assembly BW4406 1 97-04 AE TC4406-200-R<br />
B105 Gear, drive sprocket BW4406 (with 1.250” chain) 1 97-98 4406-144-002 TC4406-195-R<br />
B105 Gear, drive sprocket BW4406 (with 1” chain) 1 98-04 4406-625-005 TC4406-196-R<br />
C120 Gear, drive sprocket BW4406 (w/torque on demand) 1 97-04 4406-144-001 TC4406-197-R<br />
D138 Gear, driven sprocket BW4406 (with 1” chain) 1 98-04 AE TC4406-206-R<br />
D138 Gear, driven sprocket BW4406 (with 1.250” chain) 1 97-04 AE TC4406-205-R<br />
E140 Housing, front case BW4406 1 97-04 AE TC4406-210-R<br />
E158 Shaft, shift w/spring/cam BW4406 1 97-04 AE TC4406-215-R<br />
E156 Housing, rear case BW4406 1 97-04 AE TC4406-220-R<br />
E160 Housing, extension<br />
BW4406 casting # 4406-066-901w/speedo &<br />
sensor holes<br />
1 97-04 4406-566-004 TC4406-275<br />
TRANSFER CASE CHAINS<br />
B165 Chain, drive 86 links 1.250” wide (RP) BW4406 1 97-98 F65Z-7A029-AA HV-052<br />
B165 Chain, drive 86 links 1.250” wide (RJ) BW4406 (with TOD) 1 97-04 XL1Z-7A029-AA HV-053<br />
B165 Chain, drive 86 links 1” wide (RP) BW4406 1 98-04 XL3Z-7A029-AA HV-066<br />
ELECTRICAL COMPONENTS<br />
E178 Motor, electric shift BW4406 (7-pin rectangular connector) 1 97-04 YL2Z-7G360-AB 600-802<br />
SHIFT FORKS AND PADS<br />
E190 Pad, shift fork (nylon) range 2 97-04 E9TZ-7C430-A TC1356-28<br />
E192 Fork, aluminum range 1 97-04 4406-596-005 TC4406-123<br />
E195 Fork mode (w/torque on demand) 1 97-04 4406-096-002 TC4406-124<br />
E195 Fork mode (w/o torque on demand) 1 97-04 4406-096-007 TC4406-125<br />
NOTES<br />
BW4406<br />
© 2012 Autry Enterprises Ltd. 21
BW4407•4407<br />
BW4407<br />
A<br />
B<br />
60<br />
100<br />
PTO<br />
drive<br />
gear<br />
130<br />
bearing<br />
retainer<br />
108<br />
planetary<br />
w/input gear<br />
132<br />
drive<br />
sprocket<br />
45 66 67 68 110<br />
200<br />
134<br />
lock-up<br />
collar<br />
range<br />
slider<br />
lock-up<br />
hub<br />
112<br />
output<br />
shaft<br />
rear<br />
collar<br />
hub<br />
125<br />
126<br />
120<br />
121 123<br />
124<br />
128<br />
filter<br />
136 138 140<br />
144<br />
141 76<br />
yoke<br />
35<br />
pump<br />
5 78<br />
145<br />
nut<br />
72<br />
drive chain<br />
147 80 8 150 151 81 153<br />
154<br />
83<br />
C<br />
nut<br />
yoke<br />
shield<br />
output<br />
shaft<br />
front<br />
driven<br />
sprocket<br />
162<br />
160<br />
20<br />
163<br />
165 166<br />
220 222 225<br />
180<br />
26<br />
D<br />
vent<br />
21<br />
front<br />
case half<br />
ring gear<br />
168<br />
magnet<br />
23<br />
169<br />
shift rail<br />
176<br />
170<br />
177<br />
detent<br />
spring<br />
roller<br />
range<br />
fork<br />
178<br />
mode<br />
fork<br />
174<br />
rear<br />
case half<br />
185<br />
205<br />
4WD<br />
sensor<br />
BW4407<br />
TC4407<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal BW4407 1 96-97 AE TK-4407<br />
n/i Kit, gasket/seal BW4407 1 96-97 AE K105-943<br />
GASKETS AND RUBBER COMPONENTS<br />
n/i Gasket, adapter housing BW4407 1 96-97 04130678 13591<br />
METAL CLAD SEALS<br />
D20 Seal, metal clad front input shaft 1 96-97 F4TZ-7B215-A 205-18994<br />
D21 Seal, metal clad front output shaft 1 96-97 F4TZ-7B215-A 205-18994<br />
D26 Seal, metal clad rear output shaft 1 96-97 F4TZ-7B215-A 205-18994<br />
D23 Seal, metal clad shift shaft 1 96-97 1900-044-011 205-3687<br />
22 © 2012 Autry Enterprises Ltd.
BW4407•4407<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
FILTERS<br />
A35 Filter, oil BW4407 1 96-97 4400-238-003 TC4406-050<br />
BUSHINGS<br />
A45 Bushing input gear (inner) 1 96-97 n/a TC4407-165<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A60 Bearing, ball .830” 3.935” od 2.165” id front input shaft 1 96-97 F5TZ-7025-B 6211L<br />
A72 Bearing, ball .789” 1.971” id 3.545” od rear output shaft (front) 1 96-97 D3TZ-7065-C 6210N<br />
B76 Bearing, ball .903” 1.575” id 2.542” od rear output shaft (rear) 1 96-97 8D7065 6308N<br />
C81 Bearing, ball .708” 1.565” id 3.148” od front output shaft (front) 1 96-97 F5TZ-7025-C 6208N<br />
C83 Bearing, ball .671” 1.377” id 2.837” od front output shaft (rear) 1 96-97 F0TZ-7025-B 6207N<br />
HARD PARTS<br />
A108 Planetray assembly BW4407 (w/o PTO) 1 96-97 F5TZ-7A398-B TC4407-236<br />
A108 Planetray assembly BW4407 (w/PTO) 1 96-97 F5TZ-7A398-A TC4407-237<br />
A110 Hub, range slider BW4407 1 96-97 4407-089-003 TC4407-179-R<br />
A112 Shaft, main w/pump BW4407 1 96-97 4407-671-002 TC4407-190<br />
A120 Pump, oil assembly BW4407 1 96-97 AE TC4407-200-R<br />
B132 Sprocket, drive BW4407 1 96-97 4407-144-001 TC4407-180<br />
C154 Sprocket, driven BW4407 1 96-97 4407-144-002 TC4407-205<br />
D163 Housing, front case BW4407 1 96-97 AE TC4407-220-R<br />
D180 Housing, rear case BW4407 1 96-97 AE TC4407-225-R<br />
TRANSFER CASE CHAINS<br />
B200 Chain, drive 84 links 1.500” wide (RP) BW4407 1 96-97 F5TZ-7A029-A HV-054<br />
SHIFT FORKS AND PADS<br />
D220 Pad, shift fork (nylon) BW4407 2 96-97 E9TZ-7C430-A TC1356-28<br />
D222 Fork range 1 96-97 F5TZ-7289-A TC4407-123<br />
D225 Fork, plastic mode (4407-096-002) 1 96-97 F5TZ-7289-C TC4407-124<br />
NOTES<br />
BW4407<br />
© 2012 Autry Enterprises Ltd. 23
BW4410•4410<br />
BW4410<br />
A<br />
65<br />
99<br />
input<br />
shaft<br />
100<br />
290<br />
104 106<br />
68<br />
viscous<br />
coupling<br />
drive<br />
sprocket<br />
50 111 51<br />
sun<br />
gear<br />
70<br />
115<br />
planetary<br />
73<br />
130<br />
ring<br />
gear<br />
B<br />
80<br />
137<br />
rear<br />
output<br />
shaft<br />
142<br />
oil scoop<br />
drive chain<br />
146<br />
81 82 147 150 84<br />
5 152<br />
nut<br />
yoke<br />
164<br />
165<br />
170<br />
86 167 88<br />
C<br />
25<br />
190<br />
263 265<br />
30<br />
front<br />
output shaft<br />
shield<br />
driven<br />
sprocket<br />
D<br />
185<br />
vent<br />
26<br />
260<br />
front<br />
case half<br />
drive chain<br />
damper/guide<br />
rear<br />
case half<br />
BW4410<br />
TC4410<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearings/seals BW4410 (Explorer/Mountaineer) 1 02-06 TCRK-4410 TK-4410<br />
n/i Kit, gaskets/seals BW4410 (Explorer/Mountaineer) 1 02-06 DTK-4410 K105-964<br />
GASKETS AND RUBBER COMPONENTS<br />
n/i Gasket extension housing to adapter 1 02-06 n/a 13597<br />
METAL CLAD SEALS<br />
D25 Seal, metal clad front input shaft 1 02-06 F3TZ-7B215-A 205-16043<br />
D26 Seal, metal clad front output shaft 1 02-06 F3TZ-7B215-A 205-16043<br />
D30 Seal, metal clad rear output shaft 1 02-06 F3TZ-7B215-A 205-16043<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A65 Bearing, ball .747” 3.344” od 1.772” id front input shaft 1 02-06 F57Z-7127-A 6209N<br />
B80 Bearing, caged (cup) rear output shaft (inner) 1 02-06 BCE-1816 TC1350-135<br />
B81 Bearing, ball .708” 1.565” id 3.148” od rear output shaft (front) 1 02-06 12353016 6208N<br />
B82 Bearing, ball .510” 1.174” id 2.166” od rear output shaft (rear) 1 02-06 n/a 6006<br />
C86 Bearing, ball .671” 1.377” id 2.837” od front output shaft (front) 1 02-06 15580228 6207N<br />
C88 Bearing, ball .628” 1.180” id 2.435” od front output shaft (rear) 1 02-06 E7TZ-7025-C 6206N<br />
24 © 2012 Autry Enterprises Ltd.
BW4410•4410<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
HARD PARTS<br />
A99 Shaft, front input (28 splines) BW4410 (12 5/16” length) 1 02-06 1L2Z-7017-CA TC4410-151<br />
A104 Coupling, viscous clutch BW4410 (Explorer/Mountaineer) 1 02-06 1L2Z-7L499-BA TC4410-178<br />
A106 Gear, sprocket BW4410 (drive) 1 02-06 AE TC4410-180-R<br />
A111 Gear, sun BW4410 1 02-06 AE TC4410-185-R<br />
A115 Gear, planetary assembly BW4410 1 02-06 AE TC1372-185-R<br />
A130 Gear, planetary ring BW410 1 02-06 AE TC4410-188-R<br />
B137 Shaft, rear output BW4410 1 02-06 AE TC4410-190-R<br />
C164 Shaft, front output BW4410 1 02-06 AE TC4410-195-R<br />
C170 Gear, sprocket BW4410 (driven) 1 02-06 AE TC4410-198-R<br />
D190 Housing, front case BW4410 1 02-06 AE TC4410-205-R<br />
D265 Housing, rear case BW4410 1 02-06 AE TC4410-215-R<br />
TRANSFER CASE CHAINS<br />
A290 Chain, drive 74 links 1.250” wide (RJ) Explorer/Mountaineer BW4410 single speed 1 02-06 1L2Z-7A029-LF HV-078<br />
NOTES<br />
BW4410<br />
© 2012 Autry Enterprises Ltd. 25
BW4411•4411<br />
BW4411<br />
A<br />
B<br />
C<br />
102<br />
120<br />
97 98<br />
65 66<br />
100 70 101<br />
104<br />
121 122 123 99 68 50<br />
73<br />
106<br />
output<br />
input<br />
sun<br />
range<br />
shaft pump<br />
shaft<br />
gear planetary slider<br />
rear 3<br />
125<br />
45<br />
filter<br />
290<br />
128 130<br />
137<br />
146<br />
40 41<br />
75<br />
53<br />
133 140 142 78 295 147 150<br />
80 82<br />
5 84 152<br />
spring nut<br />
drive clutch clutch pack<br />
plate cam<br />
magnetic magnetic yoke<br />
sprocket<br />
apply<br />
housing<br />
clutch clutch<br />
plate<br />
coil coil<br />
housing<br />
drive chain<br />
165<br />
164<br />
86 167 170 330 88<br />
front<br />
output shaft shield<br />
reluctor<br />
driven<br />
sprocket wheel<br />
190 192 193 265<br />
25<br />
260<br />
30<br />
14 303<br />
D<br />
185<br />
vent<br />
26<br />
front<br />
case half<br />
ring gear<br />
315<br />
232<br />
233<br />
241<br />
242<br />
317<br />
range<br />
234 shift rail<br />
fork 245 246<br />
247<br />
upper<br />
speed sensor<br />
drive chain<br />
damper/guide<br />
300<br />
15 305<br />
rear<br />
case half<br />
lower<br />
248 electric<br />
90 speed sensor<br />
28<br />
shift motor<br />
shift<br />
shaft<br />
torsion<br />
spring<br />
shift<br />
cam<br />
BW4411<br />
TC4411<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal BW4411 1 02-06 TCRK-4411 TK-4411<br />
n/i Kit, gasket/seal BW4411 1 02-06 DTK-4411 K105-965<br />
GASKETS AND RUBBER COMPONENTS<br />
n/i Gasket extension housing to adapter 1 02-06 n/a 13597<br />
METAL CLAD SEALS<br />
D25 Seal, metal clad front input shaft 1 02-06 F3TZ-7B215-A 205-16043<br />
D26 Seal, metal clad front output shaft 1 02-06 F3TZ-7B215-A 205-16043<br />
D30 Seal, metal clad rear output shaft 1 02-06 F3TZ-7B215-A 205-16043<br />
CLUTCH PLATES<br />
B40 Friction .078” 4.727” id 31T 1-sided w/external teeth 6 02-06 138731-195 TC4405-103<br />
B41 Friction .078” 5.590” od 19T 1-sided w/internal teeth 5 02-06 138730-195 TC4405-104<br />
FILTERS<br />
A45 Filter, oil BW4411 1 02-06 400-238-002 TC4406-050<br />
26 © 2012 Autry Enterprises Ltd.
BW4411•4411<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
BUSHINGS<br />
A50 Bushing .505” 1.253” id 1.506” od front input shaft (inner) 1 02-06 n/a TC4411-164<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A65 Bearing, ball .747” 3.344” od 1.772” id front input shaft 1 02-06 F57Z-7127-A 6209N<br />
A68 Bearing, caged (cup) front input shaft (inner) 1 02-06 BCE-1816 TC1350-135<br />
B82 Bearing, ball .746” 2.832” od 1.180” id rear output shaft 1 02-06 F0TZ-7025-B 6306N<br />
C86 Bearing, ball .671” 1.377” id 2.837” od front output shaft (front) 1 02-06 15580228 6207N<br />
C88 Bearing, ball .628” 1.180” id 2.435” od front output shaft (rear) 1 02-06 E7TZ-7025-C 6206N<br />
HARD PARTS<br />
A99 Shaft, input BW4411 1 02-06 4411-189-002 TC4411-150-R<br />
A101 Gear, sun BW4411 1 02-06 1350-165-001 TC1350-177-R<br />
A102 Planetary assembly (6 pinion gears) BW4411 1 02-06 1354-659-005 TC1354-180-R<br />
A104 Hub, range BW4411 1 02-06 1354-089-002 TC1350-183A<br />
A106 Shaft, rear output BW4411 1 02-06 4405-171-008 TC4405-190-R<br />
A120 Pump, oil assembly BW4411 1 02-06 4400-508-006 TC4406-200-R<br />
B128 Gear, drive sprocket BW4411 1 02-06 4405-644-002 TC4405-196<br />
B130 Housing, clutch BW4411 1 02-06 4411-625-001 TC4411-170-R<br />
B146 Housing, magnetic clutch BW4411 1 02-06 4400-712-001 TC4411-175-R<br />
C164 Shaft, front output BW4411 1 02-06 4411-171-001 TC4411-190-R<br />
C170 Gear, driven sprocket BW4411 1 02-06 4405-144-008 TC4405-221<br />
D190 Housing, front case BW4411 1 02-06 4411-065-001 TC4411-205-R<br />
D245 Shaft, shift BW4411 1 02-06 4411-122-001 TC4411-210-R<br />
D247 Spring, shift cam BW4411 1 02-06 1350-165-008 TC1354-208<br />
D248 Cam, shift BW4411 1 02-06 4405-099-009 TC4405-099<br />
D265 Housing, rear case BW4411 1 02-06 4411-539002 TC4411-215-R<br />
TRANSFER CASE CHAINS<br />
B290 Chain, drive 74 links 1” wide (RJ) BW4411 1 02-06 XL2Z-7A029-BB HV-067<br />
ELECTRICAL COMPONENTS<br />
B295 Coil, magnetic clutch BW4411 1 02-06 4400-045-020 TC4405-180<br />
D300 Motor, electric shift BW4411 1 02-06 4411-648-007 600-809<br />
D303 Sensor, speed BW4411 (upper) 1 02-06 4400-640-043 600-840<br />
D305 Sensor, speed BW4411 (lower) 1 02-06 4400-640-044 600-841<br />
SHIFT FORKS AND PADS<br />
D315 Pad, shift fork (nylon) BW4411 2 02-06 1356-235-001 TC1356-28<br />
D317 Fork, range shift BW4411 1 02-06 4411-596-001 TC4411-123<br />
NOTES<br />
BW4411<br />
© 2012 Autry Enterprises Ltd. 27
BW4416•4416<br />
BW4416<br />
A<br />
110<br />
108 113<br />
85 86<br />
55 90<br />
57 40<br />
91<br />
115 116<br />
planetary<br />
w/input<br />
shaft/gear<br />
62 63 64 120<br />
range<br />
slider<br />
165<br />
92<br />
output<br />
shaft<br />
rear<br />
95<br />
98<br />
96 97<br />
99<br />
pump<br />
3<br />
100<br />
35<br />
filter<br />
B<br />
mode lock-up<br />
hub collar<br />
spring<br />
drive<br />
sprocket<br />
drive chain<br />
C<br />
D<br />
21<br />
clutch<br />
housing<br />
output<br />
shaft<br />
front<br />
122<br />
30 31<br />
135<br />
141<br />
136<br />
shield<br />
clutch pack<br />
72 137<br />
142 143<br />
123 65 125 126 127 128 129 171<br />
138<br />
driven<br />
sprocket<br />
190<br />
spring<br />
plate cam<br />
apply<br />
plate<br />
73<br />
45 46<br />
192 195<br />
153 154<br />
magnetic<br />
clutch<br />
coil<br />
housing<br />
156<br />
magnetic<br />
clutch<br />
coil<br />
69 131 70<br />
49 26<br />
E<br />
140<br />
vent<br />
22<br />
ring gear<br />
range<br />
fork<br />
146<br />
147<br />
mode<br />
fork<br />
shift rail<br />
24<br />
178<br />
145 148 90<br />
TC4416<br />
front<br />
case half<br />
shift<br />
shaft<br />
torsion<br />
spring<br />
shift<br />
cam<br />
rear<br />
case half<br />
electric<br />
shift motor<br />
BW4416<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal BW4416 1 01-05 TCRK-4416 TK-4416<br />
n/i Kit, gasket/seal BW4416 1 01-05 DTK-4416 K105-924<br />
GASKETS AND RUBBER COMPONENTS<br />
n/i Gasket, adapter housing BW4416 1 01-05 04130678 13591<br />
METAL CLAD SEALS<br />
E21 Seal, metal clad front input shaft 1 01-05 n/a 205-18771<br />
E22 Seal, metal clad front output shaft 1 01-05 n/a 205-18994<br />
E26 Seal, metal clad rear output shaft 1 01-05 n/a 205-18507<br />
CLUTCH PLATES<br />
C30 Friction .065” 4.727” id 31T external teeth 7 01-06 APC-183731 TC4406-103<br />
C31 Friction .065” 5.590” id 19T internal teeth 6 01-06 APC-183730 TC4406-104<br />
FILTERS<br />
A35 Filter, oil BW4416 1 01-05 4400-235-003 TC4416-050<br />
28 © 2012 Autry Enterprises Ltd.
BW4416•4416<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
BUSHINGS<br />
E49 Bushing rear extension housing 1 01-05 AE TC1356-162<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A55 Bearing, ball .709” 3.539” od 2.164” id front input shaft 1 01-05 n/a 6011N<br />
A57 Bearing, caged (cup) front input shaft (inner) 1 01-05 BK-3026 TC4406-135<br />
C70 Bearing, ball .825” 3.145” od 1.378” id rear output shaft 1 01-05 n/a 6307N<br />
D72 Bearing, ball .708” 1.565” id 3.148” od front output shaft (front) 1 01-05 F5TZ-7025-C 6208N<br />
D73 Bearing, ball .550” 2.440” od 1.380” id front output shaft (rear) 1 01-05 n/a 6007-J<br />
HARD PARTS<br />
A90 Gear, planetary assembly BW4416 1 01-05 4416-659-002 TC4416-160-R<br />
A91 Hub, range slider BW4416 1 01-05 4400-089-002 TC4416-165-R<br />
A92 Shaft, rear output BW4416 (mainshaft) 1 01-05 4416-671-004 TC4416-170-R<br />
A95 Pump, oil assembly BW4416 1 01-05 4400-508-013 TC4416-200-R<br />
B108 Hub, mode BW4416 1 01-05 4416-179-001 TC4416-172-R<br />
B110 Sleeve, mode collar BW4416 1 01-05 4416-589-001 TC4416-174-R<br />
B120 Gear, sprocket BW4416 (drive) 1 01-05 2L1Z-7177-AA TC4416-180-R<br />
C122 Housing, clutch BW4416 1 01-05 4416-625-002 TC4416-182-R<br />
C125 Plate, clutch armature BW4416 1 01-05 4416-147-001 TC4416-185-R<br />
C129 Housing, magnetic clutch BW4416 1 01-05 4400-712-001 TC4411-175-R<br />
D135 Shaft, front output BW4416 1 01-05 2L1Z-7061-BA TC4416-195-R<br />
D138 Gear, driven sprocket BW4416 (driven) 1 01-05 4406-144-001 TC4406-205-R<br />
E141 Housing, front case BW4416 1 01-05 4416-565-003 TC4416-210-R<br />
E145 Shaft, shift w/spring/cam BW4416 1 01-05 AE TC4406-215-R<br />
E147 Spring, torsion BW4416 1 01-05 1356-156-006 TC1356-207<br />
E148 Cam, electric shift BW4416 1 01-05 4406-099-004 TC1356-208<br />
E156 Housing, rear case BW4416 1 01-05 4416-147-001 TC4416-225-R<br />
TRANSFER CASE CHAINS<br />
B165 Chain, drive 86 links 1.250” wide (RJ) BW4416 1 01-05 HV-053 HV-053<br />
ELECTRICAL COMPONENTS<br />
C171 Coil, magnetic clutch BW4416 1 01-05 4400-645-017 TC4416-262<br />
E178 Motor, electric shift BW4416 1 01-05 4416-648-004 600-811<br />
SHIFT FORKS AND PADS<br />
E190 Pad, shift fork (nylon) BW4416 1 01-05 E9TZ-7C430-A TC1356-28<br />
E192 Fork, aluminum range 1 01-05 ZL3Z-7289-AA TC4406-123<br />
E195 Fork mode 1 01-05 2L1Z-7289-BA TC4416-124<br />
NOTES<br />
BW4416<br />
© 2012 Autry Enterprises Ltd. 29
NP203F•203<br />
NP203F<br />
A<br />
240<br />
140 141 65<br />
143 144<br />
160<br />
161<br />
165<br />
162<br />
input gear<br />
166<br />
range<br />
slider<br />
167<br />
68<br />
170<br />
148<br />
147<br />
mainshaft<br />
84 86 88<br />
85 87<br />
2<br />
89 90<br />
152<br />
low<br />
gear<br />
173<br />
73<br />
95<br />
154 156<br />
75<br />
80<br />
157 81<br />
bearing<br />
retainer<br />
176<br />
290 181 183<br />
178<br />
6<br />
B<br />
drive<br />
sprocket<br />
mode spring<br />
slider<br />
sun<br />
gear<br />
differential<br />
output<br />
shaft<br />
rear<br />
pump drive<br />
gear<br />
speedo<br />
nut<br />
drive chain<br />
189 104 106 108<br />
100 185 103 105 107<br />
192<br />
111<br />
C<br />
idler<br />
gear<br />
idler<br />
shaft<br />
D<br />
E<br />
197<br />
195 8<br />
yoke<br />
206<br />
120 10<br />
198<br />
115<br />
200<br />
201<br />
203<br />
202 204<br />
output<br />
shaft<br />
front<br />
driven<br />
sprocket<br />
123<br />
222 223 224<br />
209<br />
260<br />
211 265<br />
shift<br />
range rail<br />
fork<br />
mode<br />
fork<br />
215<br />
10<br />
227<br />
22<br />
219<br />
detent<br />
233 235<br />
13<br />
15<br />
125<br />
25 130<br />
35 38<br />
40<br />
225 17<br />
37<br />
F<br />
front<br />
case half<br />
14<br />
220<br />
rear<br />
case half<br />
19<br />
230<br />
128<br />
adapter<br />
housing<br />
extension<br />
housing<br />
PTO<br />
cover<br />
bearing<br />
retainer<br />
NP203F<br />
TC203F<br />
30 © 2012 Autry Enterprises Ltd.
NP203F•203<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal direct mount 1 72-79 TCRK-203F TK-203B<br />
n/i Kit, bearing/gasket/seal remote mount 1 72-75 TCRK-203FA TK-203C<br />
n/i Kit, gasket/seal direct mount 1 72-79 DTK-203F K105-905<br />
n/i Kit, gasket/seal remote mount 1 72-75 DTK-203F K105-941<br />
GASKETS AND RUBBER COMPONENTS<br />
A2 O’ring mainshaft 1 72-79 87036-S94 03821353<br />
B6 Seal (rubber) rear output yoke 1 72-79 D4TZ-7A385B 04210973<br />
D8 Seal (rubber) front output yoke 1 72-79 D4TZ-7A385B 04210973<br />
E10 O’ring shift shaft 1 72-79 377158-S 01536267<br />
F14 Gasket, power take off cover (PTO) PTO gasket 1 72-79 B9TT-7166-C 3915L<br />
n/i Gasket, adapter housing NP203 1 72-79 04130678 13591<br />
METAL CLAD SEALS<br />
F35 Seal, metal clad input gear 1 72-79 D3TZ-7B215-B 205-19255<br />
F37 Seal, metal clad front output shaft 1 72-79 D4TZ-7B215-D 205-17716<br />
F38 Seal, metal clad adapter housing 1 72-79 D4TZ-7A248-A 205-22306<br />
F40 Seal, metal clad rear output shaft 1 72-79 D4TZ-7B215-B 205-21061<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A65 Bearing, ball .789” 1.971” id 3.545” od input shaft 1 72-79 D3TZ-7065-C 6210N<br />
A68 Bearing, needle input pilot a/r 72-79 D3TZ-7120-A 02954109<br />
A73 Washer, thrust low gear 1 72-79 D4TZ-7C350-A 03821357-R<br />
A75 Bearing, ball .789” 1.971” id 3.545” od mainshaft (middle) 1 72-79 D3TZ-7065-C 6210N<br />
A80 Washer, thrust sun gear 1 72-79 D4TZ-7A385-A 03821369-R<br />
A81 Washer, thrust sun gear (lube) 1 72-79 D4TZ-7C341-A 03821370<br />
B84 Spacer, needle (w/o shoulder) sun gear (short) 1 72-79 D4TZ-7115-B 03821366-R<br />
B85 Bearing, needle sun gear a/r 79-79 D3TZ-7120-A 02954109<br />
B85 Bearing, needle .125” od .935” length sun gear a/r 72-78 D4TZ-7125-A 00666927<br />
B86 Spacer, needle (w/o shoulder) sun gear 1 72-79 D4TZ-7115-B 03821366-R<br />
B87 Bearing, needle sun gear a/r 79-79 D3TZ-7120-A 02954109<br />
B87 Bearing, needle .125” od .935” length sun gear a/r 72-78 D4TZ-7125-A 00666927<br />
B88 Spacer, needle sun gear (long) 1 72-79 D4TZ-7115-E 03821367-R<br />
B89 Bearing, needle sun gear a/r 79-79 D3TZ-7120-A 02954109<br />
B89 Bearing, needle .125” od .935” length sun gear a/r 72-78 D4TZ-7125-A 00666927<br />
B90 Spacer, needle (w/o shoulder) sun gear 1 72-79 D4TZ-7115-B 03821366-R<br />
B95 Bearing, needle rear output shaft (front) a/r 72-79 D3TZ-7120-A 02954109<br />
C100 Washer, thrust idler gear 1 72-79 D4TZ-7C341-B 03821412<br />
C103 Bearing, needle ilder gear a/r 72-79 D3TZ-7120-A 02954109<br />
C104 Spacer, needle idler gear (long) 1 72-79 D4TZ-7115-A 03821410-R<br />
C105 Bearing, needle idler gear a/r 72-79 D3TZ-7120-A 02954109<br />
C106 Spacer, needle idler gear (short) 1 72-79 D4TZ-7115-D 03821411-R<br />
C107 Bearing, needle sun gear a/r 72-79 D3TZ-7120-A 02954109<br />
C108 Spacer, needle sun gear (short) 1 72-79 D4TZ-7115-D 03821411-R<br />
C111 Washer, thrust idler gear 1 72-79 D4TZ-7C341-B 03821412<br />
D115 Bearing, ball .825” 3.145” od 1.378” id front output shaft (front) 1 72-79 8D-7065 6307N<br />
F125 Bearing, ball .825” 3.145” od 1.378” id adapter housing (front) 1 72-79 8D-7065 6307N<br />
F128 Bearing, caged (closed) front output shaft (rear) 1 72-79 TYAA-7127-A M-28161<br />
F130 Bearing, ball .825” 3.145” od 1.378” id rear output shaft (rear) 1 72-79 8D-7065 6307N<br />
n/i Bearing, needle differential pinion gears 132 72-79 D4TZ-7A672-A 03821384<br />
HARD PARTS<br />
A140 Snap ring NP203 input bearing on input gear 1 72-79 D3TZ-7070-E 03821557-R<br />
A143 Gear, input 28 splines 6 13/16” NP203 1 72-79 D4TZ-7158-A 00011895-R<br />
A143 Gear, input 31 splines 4 25/32” NP203 1 72-79 D4TZ-7017-A 00011874<br />
A144 Sleeve, range slider NP203 1 72-79 D4TZ-7100-B 03821362<br />
A147 Shaft, main NP203 1 72-79 D4TZ-7017-B 03821352-R<br />
NP203F<br />
© 2012 Autry Enterprises Ltd. 31
NP203F•203<br />
NP203F<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
HARD PARTS (CONTINUED)<br />
A148 Pin, thrust washer NP203 2 72-79 D3TZ-7C018-A 02952592-R<br />
A152 Gear, low speed 42T NP203 1 72-79 D4TZ-7100-D 03821354-R<br />
A154 Retainer 7 3/32” x 1 5/8” NP203 1 72-79 D4TZ-7050-A 03821359-R<br />
B160 Snap ring 3” od NP203 1 72-79 D4TZ-7917-A 03821372-R<br />
B161 Gear, sprocket 2 1/2” (1st design) NP203 (drive) 1 72-79 D6TZ-7177-A 03898368-R<br />
B161 Gear, sprocket 2” (2nd design) NP203 (drive) 1 78-79 D4TZ-7177-A 04115335<br />
B162 Snap ring 3” od NP203 (drive sprocket) 1 72-79 D4TZ-7917-A 03821372-R<br />
B165 Sleeve, mode slider NP203 1 72-79 D4TZ-7100-A 03821374-R<br />
B170 Gear, sun NP203 1 72-79 D4TZ-7060-A 03821365-R<br />
B173 Carrier, w/spider gears NP203 1 72-79 D8TZ-7A219-A 04115251-R<br />
B178 Pump, oil 38 splines (nylon) NP203 1 72-79 D8TZ-7C010-A 03894957<br />
B183 Nut NP203 1 72-79 372631-S 02954140-R<br />
C192 Shaft, idler gear NP203 1 72-79 D4TZ-7111-A 03821407-R<br />
D200 Ring, bearing outer NP203 1 72-79 C5TZ-7070-A 02507820<br />
D202 Snap ring 3” od NP203 (driven sprocket) 1 72-79 D4TZ-7917-A 03821372-R<br />
D203 Gear, sprocket 2 1/2” (1st design) NP203 (driven sprocket) 1 72-79 D6TZ-7177-A 03898368-R<br />
D203 Gear, sprocket 2” (2nd design) NP203 (driven) 1 72-79 D4TZ-7177-A 04115335<br />
D204 Snap ring 3” od NP203 (driven sprocket) 1 72-79 D4TZ-7917-A 03821372-R<br />
F230 Retainer, front output shaft NP203 1 72-79 D4TZ-7067-A 03821376-R<br />
F230 Retainer, front output shaft NP203 1 72-79 D3TZ-7085-D 02954130-R<br />
TRANSFER CASE CHAINS<br />
B240 Chain, drive 98 links 2.500” wide (RJ) NP203 1 72-79 D4TZ-7A029A HV-005<br />
B240 Chain, drive 98 links 2” wide (RJ) NP203 1 78-79 D8TZ-7A029A HV-009<br />
SHIFT FORKS AND PADS<br />
E260 Fork, range shift NP203 1 72-79 D4TZ-7289-A 03410038<br />
E265 Fork, mode shift NP203 1 72-79 D4TZ-7289-B 03820877-R<br />
SPEEDO GEARS<br />
B290 Gear, speedo 5T NP203 1 72-79 03732038 03732038<br />
NOTES<br />
32 © 2012 Autry Enterprises Ltd.
Engine Hanger Parts<br />
T-1256 Parts List<br />
The Ultimate Engine Hanger<br />
Engine Hanger Parts<br />
012-128 front leg (2)<br />
012-127 2-link chain (3)<br />
012-115 bottom bracket w/nut (2)<br />
012-120 s-hook (3)<br />
012-116 shock tower bracket (2)<br />
012-019 shock tower adapter (2)<br />
012-111 3" 1/2"thread bolt (2)<br />
012-118 j-hook (3)<br />
012-112 2" 1/2"thread bolt (2)<br />
012-126 top support bracket (9)<br />
012-125 lower front leg bracket (2)<br />
012-124 thrust bearing (3)<br />
012-109 square poly plug (12)<br />
012-110 1/2" flat washer (6)<br />
012-121 wall hanger (1)<br />
012-123 front leg rubber pad (2)<br />
012-114 1/2" jam nut (2)<br />
012-113 1/2" hex nut (2)<br />
012-108 wall hanger peg (7)<br />
012-117 j-hook handle (3)<br />
012-106 side cross bar (2)<br />
012-122 front leg handle (2)<br />
all parts are sold separately<br />
012-107 cross bar (1)<br />
© 2012 Autry Enterprises Ltd. 33
NP205F•205<br />
NP205F<br />
A<br />
B<br />
C<br />
D<br />
105 60 107 108<br />
151<br />
150<br />
30<br />
input gear<br />
(input shaft)<br />
nut<br />
nut<br />
range<br />
slider<br />
yoke<br />
112<br />
62 110 63 64 65 66 69<br />
output<br />
shaft rear<br />
shims<br />
high<br />
gear<br />
idler gear<br />
spacer<br />
output shaft<br />
front<br />
low<br />
gear front<br />
121 122 78 79 80 125<br />
82 83<br />
126 128<br />
131 8<br />
155 156<br />
157<br />
shift<br />
rail<br />
133 134 85 86 137 138<br />
190<br />
mode<br />
fork<br />
33<br />
192<br />
160 14<br />
32<br />
162 15<br />
input bearing<br />
retainer<br />
165<br />
210<br />
70 113 115 72<br />
speedo<br />
drive<br />
gear<br />
idler shaft<br />
88 89 90 141<br />
17<br />
166<br />
PTO<br />
cover<br />
cover 98<br />
142<br />
low<br />
gear rear<br />
18 167<br />
19 169<br />
73 116 117<br />
92<br />
extension<br />
housing<br />
22 175<br />
yoke<br />
20<br />
5 118<br />
nut<br />
170 35<br />
bearing<br />
retainer<br />
range<br />
fork<br />
front output<br />
bearing<br />
retainer<br />
case<br />
bearing<br />
retainer<br />
163 96<br />
TC205F<br />
NP205F<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal direct mount 1 71-89 TCRK-205F TK-205C<br />
n/i Kit, bearing/gasket/seal remote mount 1 71-77 TCRK-205FA TK-205D<br />
n/i Kit, gasket/seal direct mount 1 71-89 DTK-205F K105-919<br />
n/i Kit, gasket/seal remote mount 1 71-77 DTK-205FA K105-942<br />
GASKETS AND RUBBER COMPONENTS<br />
A5 Seal (rubber) output yoke 1 71-89 D4TZ-7B368-A 04210973<br />
A8 Seal (rubber) front output shaft yoke 1 71-89 D4TZ-7B368-A 04210973<br />
D17 Gasket, power take off cover (PTO) NP205 1 71-89 B9TT-7166-C 3915L<br />
n/i Gasket, adapter housing NP205 1 71-89 04130678 13591<br />
METAL CLAD SEALS<br />
D30 Seal, metal clad shift shaft 2 71-89 D3TZ-7288-A 205-7464<br />
D32 Seal, metal clad front output shaft 1 71-89 D37Z-7B215-A 205-21213<br />
D33 Seal, metal clad front input shaft 1 71-89 D37Z-7B215-A 205-21213<br />
D35 Seal, metal clad rear output shaft 1 71-89 D37Z-7B215-A 205-21213<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A60 Bearing, ball .825” 3.145” od 1.378” id input gear (direct mount) 1 71-89 8D-7065 6307N<br />
A60 Bearing, ball .789” 1.971” id 3.545” od input gear (remote mount) 1 71-98 D3TZ-7065-C 6210N<br />
A62 Bearing, needle rear output shaft (pilot) 15 71-89 D3TZ-7120-A 02954109<br />
A63 Washer, thrust (w/tab) low gear 1 71-89 D3TZ-7067-A 03491282-R<br />
A64 Bearing, needle low gear (upper) 32 71-89 D3TZ-7A672-A 01949834<br />
A65 Spacer, needle NP205 1 71-89 D3TZ-7080-A 02954112-R<br />
A66 Bearing, needle low gear (upper) 32 71-89 D3TZ-7A672-A 01949834<br />
34 © 2012 Autry Enterprises Ltd.
NP205F•205<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
WASHERS/BEARINGS/RACES/SHIMS (CONTINUED)<br />
A69 Washer, thrust (w/tab) low gear 1 71-89 D3TZ-7067-A 03491282-R<br />
A70 Washer, thrust (w/o tab) low gear 1 71-89 D3TZ-7067-B 02954113-R<br />
A72 Bearing, caged (open) rear output shaft support 1 71-89 C4TZ-7127-A B3216<br />
A73 Bearing, ball .825” 3.145” od 1.378” id rear output shaft 1 71-89 8D-7065 6307N<br />
B78 Bearing, cone idler gear 1 71-89 D3TZ-7065-A BR2793<br />
B79 Bearing, cup idler gear 1 71-89 2910220 BR2720<br />
B82 Bearing, cup idler gear 1 71-89 2910220 BR2720<br />
B83 Bearing, cone idler gear 1 71-89 D3TZ-7065-A BR2793<br />
C85 Bearing, ball .825” 3.145” od 1.378” id front output shaft 1 71-89 8D-7065 6307N<br />
C86 Washer, thrust (w/tab) high gear 1 71-89 D3TZ-7067-A 03491282-R<br />
C88 Bearing, needle low gear (lower) 32 71-89 D3TZ-7A672-A 01949834<br />
C89 Spacer, needle low gear (lower) 1 71-89 D3TZ-7080-A 02954112-R<br />
C90 Bearing, needle low gear (lower) 32 71-89 D3TZ-7A672-A 01949834<br />
C92 Washer, thrust (w/o tab) low gear 1 71-89 D3TZ-7067-B 02954113-R<br />
D98 Bearing, caged (closed) front output shaft (rear) 1 71-89 TYAA-7127-A M-28161<br />
HARD PARTS<br />
A105 Ring, bearing outer NP205 1 71-89 02124518 02124518-R<br />
A107 Gear, input (32 splines) NP205 (remote mount) 1 71-89 D3TZ-7017-A 02954104<br />
A107 Gear, input (31 splines) NP205 (direct mount) 1 71-89 D7TZ-7017-B 00011656<br />
A108 Sleeve, sliding NP205 (range) 1 71-89 D3TZ-7100-B 02954116<br />
A110 Shaft, rear output (w/bolt-on yoke) 34-38-32-8-13/16L 1 71-89 D3TZ-7061-B 04106561<br />
A112 Gear, 25T NP205 (low gear upper) 1 71-89 D3TZ-7100-C 02952589-R<br />
A115 Spacer, sleeve rear output shaft 1 71-89 02225025 02225025-R<br />
A116 Ring, bearing outer rear output shaft 1 71-89 02124518 02124518-R<br />
A118 Nut NP205 1 71-89 372631S 02954140-R<br />
B121 Nut idler gear 1 71-89 372631S 02954140-R<br />
B125 Gear, idler NP205 1 71-89 D3TZ-7142-A 02954119-R<br />
B126 Spacer, idler gear bearing NP205 1 71-89 D3TZ-7125-A 02954121-R<br />
B128 Shaft, idler NP205 1 71-89 D3TZ-7140-A 02954122-R<br />
C131 Nut front output shaft 1 71-89 372631S 02954140-R<br />
C134 Ring, bearing outer front output shaft 1 71-89 02124518 02124518-R<br />
C137 Gear,35T NP205 1 71-89 D3TZ-7100-A 02954124-R<br />
C138 Shaft, front output 34-32-9 3/8” Length 1 71-89 D3TZ-7061-A 03491281-R<br />
C141 Sleeve, sliding NP205 (mode) 1 71-89 D3TZ-7100-B 02954116<br />
C142 Gear, 25T NP205 (low gear lower) 1 71-89 D3TZ-7100-C 02952589-R<br />
D150 Link, shift rail NP205 1 71-89 D3TZ-7B106-A 03732041-R<br />
D155 Shaft, rear shift 3/4” od x 7 3/32” length 1 71-89 D3TZ-7240-A 00011405-R<br />
D157 Shift, front shift 3/4” od x 8 3/4” length 1 71-89 D3TZ-7240-B 00011406-R<br />
D167 Cover, idler shaft NP205 1 71-89 D3TZ-7085-C 00927365-R<br />
D170 Retainer, rear output shaft bearing 1 3/16 wide 1 71-89 D3TZ-7085-A 02954134-R<br />
D175 Retainer, front output shaft NP205 1 71-89 D3TZ-7085-A 02954130-R<br />
n/i Pin, thrust washer NP205 2 71-89 D3TZ-7C018-A 02952592-R<br />
SHIFT FORKS AND PADS<br />
D190 Fork, shift NP205 (mode) 1 71-89 D3TZ-7289-A 02954135-R<br />
D192 Fork, shift NP205 (range) 1 71-89 D3TZ-7289-A 02954135-R<br />
NOTES<br />
NP205F<br />
© 2012 Autry Enterprises Ltd. 35
NP208F•208•208F<br />
NP208F<br />
A<br />
B<br />
160 80 82 83 162 86<br />
plate<br />
95<br />
88<br />
165<br />
drive<br />
sprocket<br />
89 166 167 169<br />
50 90 170<br />
input gear<br />
planetary ring<br />
mainshaft<br />
gear<br />
265<br />
178 180 98 99 100 101 182<br />
184<br />
103 106 186 310<br />
35<br />
190 192<br />
119 195 10 197<br />
pump speedo<br />
drive<br />
gear<br />
pump<br />
housing<br />
172<br />
yoke<br />
173<br />
nut<br />
175<br />
C<br />
200 15<br />
202 125<br />
detent<br />
spring<br />
36<br />
yoke<br />
D<br />
37<br />
216<br />
18 219<br />
217<br />
215<br />
front<br />
case half<br />
126 drive chain<br />
130<br />
127 129<br />
132<br />
206<br />
128<br />
208 131 133<br />
205<br />
135<br />
280<br />
221<br />
range<br />
fork<br />
output shaft<br />
front<br />
223<br />
20 226 145 227<br />
282<br />
284<br />
290<br />
240 243<br />
mode<br />
fork<br />
driven<br />
sprocket<br />
NP208F<br />
TC208F<br />
36 © 2012 Autry Enterprises Ltd.<br />
246<br />
shift<br />
rail<br />
249<br />
magnet<br />
250<br />
25<br />
rear<br />
case half<br />
252<br />
vent<br />
28<br />
255<br />
extension<br />
housing<br />
270<br />
switch<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal NP208 1 80-86 TCRK-208FA TK-208A<br />
n/i Kit, gasket/seal NP208 1 80-86 DTC-208 K105-908<br />
n/i Kit, small parts NP208 1 80-86 AE SP208-50<br />
GASKETS AND RUBBER COMPONENTS<br />
B10 Seal (rubber) rear output yoke 1 80-86 D4TZ-7B368-A 04210973<br />
C15 Seal (rubber) front output shaft yoke 1 80-86 D4TZ-7B368-A 04210973<br />
D20 O’ring shift shaft 1 80-86 370367S 3547L<br />
n/i Gasket, adapter housing NP208 1 80-86 04130678 13591<br />
METAL CLAD SEALS<br />
B35 Seal, metal clad oil pump housing 1 80-86 E0TZ-7B215-A 205-22306<br />
D36 Seal, metal clad front input gear 1 80-86 205-19255 205-19255<br />
D37 Seal, metal clad front output shaft 1 80-86 E0TZ-7B215-B 205-18771<br />
D40 Seal, metal clad rear output shaft 1 80-86 D9TZ-7B215-A 205-18771<br />
BUSHINGS<br />
A50 Bushing, ring gear NP208 1 80-86 00013721 00013721<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A80 Bearing, caged (cup) 2 9/32” od front input shaft 2 80-86 E0TZ-7120-A 04269185<br />
A82 Washer, thrust 3/32” thick 2” id input gear 1 80-86 4167933 04167933-R<br />
A83 Bearing, thrust 1 31/32” id front input gear 1 80-86 E0TZ-7C096-A 04167934<br />
A86 Bearing, caged 1.500” od input gear (inner) 1 80-86 E0TZ-7065-A 04269187<br />
A88 Bearing, thrust mainshaft 1 80-86 E1TZ-7C096-B 04269182<br />
A89 Washer, thrust 3.435” od planetary to ring gear 1 80-86 E0TZ-7D484-A 04167953<br />
A90 Washer, thrust NP208 1 80-86 4219064 04219064-R<br />
B95 Washer, thrust 1/32” thick 2 19/64” id sprocket carrier 1 80-86 E1TZ-7A385-A 04269177-R<br />
B98 Spacer, sprocket carrier rollers NP208 1 80-86 E0TZ-7115-A 04167985-R<br />
26<br />
257<br />
40
NP208F•208•208F<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
WASHERS/BEARINGS/RACES/SHIMS (CONTINUED)<br />
B99 Bearing, needle .125” od .935” length sprocket carrier 60 80-86 D4TZ-7145-A 00666927<br />
B100 Spacer, sprocket carrier rollers NP208 1 80-86 E0TZ-7115-A 04167985-R<br />
B101 Bearing, needle .125” od .935” length NP208 60 80-86 D4TZ-7145-A 00666927<br />
B103 Spacer, sprocket carrier rollers NP203 1 80-86 E0TZ-7115-A 04167985-R<br />
B106 Washer, thrust 5/32” 2 16/64” id sprocket thrust 1 83-86 E3TZ-7C341-A 04329330-R<br />
B106 Washer, thrust 2 19/64” id 5/32” thick sprocket thrust 1 80-82 E1TZ-7C341-A 04219091-R<br />
B119 Bearing, ball .671” 1.377” id 2.837” od rear output shaft 1 80-86 C3AZ-7025-B 6207N<br />
C125 Bearing, caged 2.125” od front output shaft (front) 1 80-86 E0TZ-7127-B B2816<br />
C127 Washer, thrust 3/32” thick front output shaft (front) 1 80-86 E0TZ-7119-A 04167992<br />
C128 Bearing, thrust 1.750” id 2.500” od front output shaft (front) 1 80-86 E0TZ-D234-A 04167993<br />
C129 Washer, thrust 1/32” thick front output shaft (front) 1 80-86 E0TZ-7119-B 04167994<br />
C131 Washer, thrust 3/32” thick front output shaft (rear) 1 80-86 E0TZ-7119-A 04167992<br />
C132 Bearing, thrust 1.750” id 2.500” od front output shaft (rear) 1 80-86 E0TZ-D234-A 04167993<br />
C133 Washer, thrust 1/32” thick front output shaft (rear) 1 80-86 E0TZ-7119-B 04167994<br />
C135 Bearing, caged (open) 1.875” od front output shaft (rear) 1 80-86 E0TZ-7127-A 04269189<br />
HARD PARTS<br />
A160 Plate, low range lock 31T NP208 1 80-86 E0TZ-7B442-A 04167931-R<br />
A162 Gear, input drive 45T (31 splines) 31 splines 5 5/64” length 1 80-86 E0TZ-7017-A 00013779-R<br />
A165 Gear, planetary assembly NP208 1 80-86 E0TZ-7A398-A 04329198-R<br />
A166 Gear, planetary ring w/hub NP208 1 80-82 E0TZ-7A153-A 04167954-R<br />
A166 Gear, ring w/o hub NP208 1 82-86 E1TZ-7A153-A 04219060-R<br />
A167 Web, hub assembly NP208 1 82-86 4295115 04295115<br />
A170 Snap ring 3” od 2 5/8” id 3” od 1 80-86 D4TZ-7917-A 03821372-R<br />
A172 Shaft, rear output w/hub 52-16-38T 14 23/64” length 1 80-86 E3TZ-7061-L 04329194-R<br />
B178 Carrier, sprocket 32T NP208 1 80-86 E0TZ-7C115-B 04269214-R<br />
B180 Snap ring 3 1/6” id 3/32” thick 1 80-86 E0TZ-7917-C 04167984-R<br />
B182 Sprocket, drive 32T internal/34T external 1 80-86 E1TZ-7177-A 04269178-R<br />
B184 Ring, sprocket carrier retaining 2 7/64” id 1 80-86 E0TZ-7917-A 04167987-R<br />
B186 Pump, oil 38 splines (nylon) 2 7/32” od 1 80-86 D8TZ-7C010-A 03894957<br />
B190 Housing, oil pump NP208 1 80-86 E0TZ-7A151-A 04210602<br />
B192 Ring, bearing retainer NP208 1 80-86 4210984 04210984-R<br />
B197 Nut NP208 (rear output shaft yoke) 1 80-86 04167924 04167924-R<br />
C200 Nut NP208 (front output shaft yoke) 1 80-86 04167924 04167924-R<br />
C205 Shaft, front output 61T (32 splines) 6 15/16” length 1 80-86 E1TZ-7061-A 04167730-R<br />
C206 Sprocket, driven 61T NP208 1 80-86 E1TZ-7177-B 04746259-R<br />
D221 Shaft, w/rooster cone NP208 1 80-86 E0TZ-7F063-A 00013722-R<br />
D243 Spring, shift mode fork NP208 1 80-86 E0TZ-7219-A 04167975-R<br />
D246 Rail, shift 5/8” od 8 11/16” length 1 80-86 E0TZ-7240-A 04167965-R<br />
D252 Plug w/gasket NP208 2 80-86 E0TZ-7A010-A 04210616-R<br />
n/i Bolt, extension/case NP208 4 80-86 E0TZ-7A443-A 04210617-R<br />
TRANSFER CASE CHAINS<br />
B265 Chain, drive 84 links 1.250” wide (RP) NP208 1 80-86 E0TZ-7A029-A HV-012<br />
ELECTRICAL COMPONENTS<br />
D270 Switch, lockout NP208 1 80-86 E0TZ-7E440-A 04168000<br />
SHIFT FORKS AND PADS<br />
D280 Pad, fork (nylon) range 2 80-81 04167969 04167969<br />
D282 Pad, fork (nylon) range 1 80-81 04167970 04167970<br />
D284 Fork, range shift NP208 1 80-81 E1TZ-7289-A 00015111-R<br />
D284 Fork, range shift NP208 (webb style hub ) 1 82-86 E1TZ-7289-B 00015380<br />
D290 Fork, shift mode 3 31/32” span 1 80-86 E0TZ-7289-B 04167974-R<br />
SPEEDO GEARS<br />
B310 Gear, speedo drive 8T NP208 1 80-86 D5TZ-17285-A 00013172<br />
B310 Gear, speedo drive 7T NP208 1 80-86 C3TZ-17285-A 00011392<br />
NP208F<br />
© 2012 Autry Enterprises Ltd. 37
NV271F•271F<br />
90<br />
65 91 92 66 67<br />
93<br />
68<br />
70<br />
95<br />
96<br />
A<br />
NV271F<br />
B<br />
97 99 105<br />
mode<br />
hub<br />
mode<br />
slider<br />
input gear<br />
range<br />
planetary slider<br />
165<br />
109<br />
106 108 110 73 113 114<br />
25<br />
107<br />
111<br />
clutch<br />
gear<br />
sprocket<br />
hub drive<br />
sprocket<br />
output<br />
shaft<br />
rear<br />
3<br />
116<br />
4<br />
117<br />
115<br />
pump<br />
C<br />
26<br />
130<br />
118 119<br />
7<br />
vent<br />
131<br />
yoke<br />
120<br />
shield<br />
121<br />
132 133<br />
76<br />
122<br />
123<br />
output<br />
shaft<br />
front<br />
drive chain<br />
124<br />
driven<br />
sprocket<br />
147<br />
125<br />
148<br />
87 29<br />
5<br />
filter<br />
35<br />
151 152<br />
16<br />
D<br />
27<br />
134<br />
135 9<br />
136<br />
detent<br />
front<br />
case half<br />
ring gear<br />
137<br />
138 139<br />
10 80<br />
81 11 82 83 140<br />
85<br />
190 191 195<br />
192<br />
193<br />
196<br />
199<br />
150<br />
146<br />
magnet<br />
rear<br />
case half<br />
149<br />
175<br />
4WD<br />
sensor<br />
17<br />
NP271F<br />
range mode<br />
fork fork TC271F<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal NV271 1 99-08 AE TK-271<br />
n/i Kit, gasket/seal NV271 1 99-08 AE K105-922<br />
GASKETS AND RUBBER COMPONENTS<br />
B3 O’ring oli filter tube 1 99-08 n/a TC231-018<br />
n/i Gasket, adapter housing NV271 1 99-08 04130678 13591<br />
METAL CLAD SEALS<br />
B25 Seal, metal clad oil pump housing 1 99-08 E0TZ-7B215-A 205-22306<br />
D26 Seal, metal clad front input shaft 1 99-08 F81Z-7B215-AA 205-21239<br />
D27 Seal, metal clad front output shaft 1 99-08 F81Z-7B215-BA 205-21241<br />
D29 Seal, metal clad rear output shaft 1 99-08 F81Z-7B215-BA 205-21241<br />
FILTERS<br />
B35 Filter, oil screen filter tube to pump 1 99-08 F81Z-7A098-AB TC241-050<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A65 Bearing, ball .830” 3.935” od 2.165” id front input shaft (gear) 1 99-08 F71Z-7025-AA 6211L<br />
A68 Bearing, caged (cup) front input shaft (rear) 1 99-08 F71Z-7120-AA TC271-169<br />
B73 Bearing, ball rear output shaft (middle) 1 99-08 F81Z-7015-AA 6212N<br />
C76 Bearing, ball .709” 3.539” od 2.164” id front output shaft (front) 1 99-08 F81Z-7025-BA 6011N<br />
D85 Bearing, caged (cup) front output shaft (rear) 1 99-08 F81Z-7127-AA TC271-125<br />
D87 Bearing, caged (open) rear extension housing (B3416) 1 99-08 F81Z-7118-BA TC271F-128<br />
38 © 2012 Autry Enterprises Ltd.
NV271F•271F<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
HARD PARTS<br />
A93 Gear, front input 24T NV271 (NV26605) 1 99-08 F81Z-7017-BA TC271F-170<br />
A93 Gear, front input 34T NV271 1 99-08 NV44631 TC271F-171<br />
A93 Gear, front input 31T NV271 (NV24257) 1 99-08 F81Z-7017-AA TC271F-172<br />
A95 Gear, planetary (narrow teeth) NV271 1 99-08 F81Z-7A398-AA TC241-161<br />
A95 Gear, planetary (narrow teeth) NV271 1 99-08 AE TC241-161-R<br />
A96 Hub, range shift 1.970” oh NV271 (.318” wide fork groove) 1 99-02 F81Z-7100-AA TC247-120<br />
A96 Hub, range shift NV271 (.368” wide fork groove) 1 03-08 NV38307 TC271-178<br />
B99 Hub, inner synchronizer NV271 1 99-08 AE TC271-179-R<br />
B105 Sleeve, synchronizer (mode)(small) NV271 1 99-08 AE TC241-140-R<br />
B106 Gear, clutch (mode) NV271 1 99-08 F81Z-7C215-AA TC271-181-R<br />
B108 Hub, drive sprocket NV271 1 99-08 F81Z-7W060-BA TC271-182-R<br />
B109 Gear, sprocket NV271 (drive) 1 99-08 F81Z-7177-AA TC271-185<br />
B109 Gear, sprocket NV271 (drive) 1 99-08 AE TC271-185-R<br />
B111 Kit, rear output shaft includes range fork/range slider 1 99-08 NV43219K TC271F-191<br />
B111 Shaft, rear output NV271 1 99-08 AE TC271F-190-R<br />
B115 Pump assembly NV271 1 99-08 F81Z-7A149-AA TC271-200<br />
B115 Pump assembly NV271 1 99-08 AE TC271-200-R<br />
C123 Shaft, front output NV271 1 99-08 F81Z-7061-BA TC271-205-R<br />
C124 Gear, sprocket NV271 (driven) 1 99-08 F81Z-7177-AA TC271-185<br />
C124 Gear, sprocket NV271 (driven) 1 99-08 AE TC271-185-R<br />
D131 Housing, front case NV271 1 99-08 F81Z-7005-AA TC271F-210<br />
D131 Housing, front case NV271 1 99-08 AE TC271F-210-R<br />
D147 Housing, rear case NV271 1 99-08 F81Z-7005-BA TC271F-220<br />
D147 Housing, rear case NV271 1 99-08 AE TC271F-220-R<br />
D149 Housing, rear extension NV271 1 99-08 AE TC271F-223-R<br />
n/i Tool, linkage nut remover NV271 1 99-08 T-271 ADV-T-271<br />
TRANSFER CASE CHAINS<br />
B165 Chain, drive 98 links 1.500” wide (RP) NV271 1 99-08 HV-064 HV-064<br />
ELECTRICAL COMPONENTS<br />
D175 Sensor, 4WD NV271 1 99-08 n/a TC271F-265<br />
SHIFT FORKS AND PADS<br />
D190 Pad, fork (nylon) range 2 99-08 NV37284 TC261-28<br />
D191 Pad, fork (nylon) range (ends) 2 99-08 04167969 04167969<br />
D192 Pad, fork (nylon) range (center) 1 99-08 04338376 04338376<br />
D193 Fork, range shift (iron) NV271 (#17524) 1 99-08 NV17543 TC241D-123<br />
D193 Fork, range shift NV271 (#41816) 1 03-08 n/a TC271D-123<br />
D195 Pad, fork (nylon) mode (ends) 2 99-08 F81Z-7C430-BA 04167969<br />
D197 Pad, fork (nylon) mode fork (center) 1 99-08 F81Z-7C430-DA 04219073<br />
D199 Fork, mode shift NV271 1 99-08 F81Z-7289-AA TC271-124<br />
NOTES<br />
NV271F<br />
© 2012 Autry Enterprises Ltd. 39
NV273F•273F<br />
90<br />
65 91 92 66 67<br />
93<br />
68<br />
70<br />
95<br />
96<br />
A<br />
NV273F<br />
B<br />
97 98 100<br />
99 101102 103 105 104<br />
mode<br />
hub<br />
syncro<br />
rings<br />
mode<br />
slider<br />
input gear<br />
range<br />
planetary slider<br />
165<br />
109<br />
106 108 110 73 113 114<br />
25<br />
107 111<br />
clutch<br />
gear<br />
sprocket<br />
hub drive<br />
sprocket<br />
output<br />
shaft<br />
rear<br />
3<br />
116<br />
4<br />
115<br />
pump<br />
drive chain<br />
117<br />
5<br />
118<br />
7<br />
119<br />
120<br />
121 76 122<br />
124<br />
123 125<br />
filter<br />
35<br />
C<br />
26<br />
130<br />
vent<br />
yoke<br />
shield<br />
131 132 133<br />
output<br />
shaft<br />
front<br />
driven<br />
sprocket<br />
147<br />
148<br />
87 29<br />
151<br />
16<br />
152<br />
D<br />
ring gear<br />
85 146<br />
27<br />
190 149<br />
191 magnet<br />
134 177<br />
135 9 136<br />
192 195<br />
197<br />
rear<br />
front<br />
case half<br />
case half<br />
detent<br />
140 193<br />
82<br />
142<br />
83<br />
199 150<br />
138 80<br />
137 10 11<br />
electric<br />
range mode<br />
shift motor NP273F<br />
fork fork TC273F<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal NV273 1 99-08 AE TK-271<br />
n/i Kit, gasket/seal NV273 1 99-08 AE K105-922<br />
GASKETS AND RUBBER COMPONENTS<br />
B3 O’ring oil filter tube 1 99-08 n/a TC231-018<br />
n/i Gasket, adapter housing NV273 1 99-08 04130678 13591<br />
METAL CLAD SEALS<br />
B25 Seal, metal clad oil pump housing 1 99-08 E0TZ-7B215-A 205-22306<br />
D26 Seal, metal clad front input shaft 1 99-08 F81Z-7B215-AA 205-21239<br />
D27 Seal, metal clad front output shaft 1 99-08 F81Z-7B215-BA 205-21241<br />
D29 Seal, metal clad rear output shaft 1 99-08 F81Z-7B215-BA 205-21241<br />
FILTERS<br />
B35 Filter, oil screen NV273 1 99-08 NV16217 TC241-050<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A65 Bearing, ball .830” 3.935” od 2.165” id front input shaft (front) 1 99-08 F81Z-7025-AA 6211L<br />
A68 Bearing, caged (cup) front input shaft (rear) 1 99-08 F71Z-7120-AA TC271-169<br />
B73 Bearing, ball rear output shaft (middle) 1 99-08 F81Z-7015-AA 6212N<br />
C76 Bearing, ball .709” 3.539” od 2.164” id front output shaft (front) 1 99-08 F81Z-7025-BA 6011N<br />
40 © 2012 Autry Enterprises Ltd.
NV273F•273F<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
WASHERS/BEARINGS/RACES/SHIMS (CONTINUED)<br />
D85 Bearing, caged (cup) front output shaft (rear) 1 99-08 F81Z-7127-AA TC271-125<br />
D87 Bearing, caged (open) rear extension housing 1 99-08 F81Z-7118-BA TC271F-128<br />
HARD PARTS<br />
A93 Gear, front input 24T NV273 1 99-08 F81Z-7017-BA TC271F-170<br />
A93 Gear, front input 34T NV273 1 99-08 NV44631 TC271F-171<br />
A93 Gear, front input 31T NV273 1 99-08 F81Z-7017-AA TC271F-172<br />
A95 Gear, planetary (narrow teeth) NV273 1 99-08 F81Z-7A398-AA TC241-161<br />
A95 Gear, planetary (narrow teeth) NV273 1 99-08 AE TC241-161-R<br />
A96 Hub, range shift 1.970” oh NV273 1 99-02 F81Z-7100-AA TC247-120<br />
A96 Hub, range shift NV273 1 03-08 NV38307 TC271-178<br />
B98 Spring, synchronizer (mode)(small) NV273 1 99-08 AE 04329524-R<br />
B99 Hub, inner synchronizer NV273 1 99-08 AE TC271-179-R<br />
B100 Strut, synchronizer NV273 3 99-08 AE 04446459-R<br />
B101 Spring, synchronizer (mode)(small) NV273 1 99-08 AE 04329524-R<br />
B102 Ring, inner synchronizer NV273 1 99-08 NV26549 TC273-183B<br />
B103 Ring, middle synchronizer (friction) NV373 1 99-08 NV30130 TC273-183A<br />
B104 Ring, outer synchronizer NV273 1 99-08 NV30131 TC273-183<br />
B105 Sleeve, synchronizer (mode)(small) NV273 1 99-08 AE TC241-140-R<br />
B106 Gear, clutch (mode) NV273 1 99-08 AE TC271-181-R<br />
B108 Hub, drive sprocket NV273 1 99-08 F81Z-7W060-BA TC271-182-R<br />
B109 Gear, sprocket drive 1 99-08 F81Z-7177-AA TC271-185<br />
B109 Gear, sprocket drive 1 99-08 AE TC271-185-R<br />
B111 Shaft, rear output NV273 1 99-08 AE TC273F-190-R<br />
B111 Shaft, rear output includes range fork/range slider 1 99-08 NV43219 TC273F-191<br />
B115 Pump assembly NV273 1 99-08 F81Z-7A149-AA TC271-200<br />
B115 Pump assembly NV273 1 99-08 AE TC271-200-R<br />
C123 Shaft, front output NV273 1 99-08 F81Z-7061-BA TC271-205-R<br />
C124 Gear, sprocket driven 1 99-08 F81Z-7177-AA TC271-185<br />
C124 Gear, sprocket driven 1 99-08 AE TC271-185-R<br />
D131 Housing, front case NV273 1 99-08 n/a TC273F-210<br />
D131 Housing, front case NV273 1 99-08 AE TC273F-210-R<br />
D147 Housing, rear case NV273 1 99-08 n/a TC273F-220<br />
C147 Housing, rear case NV273 1 99-08 AE TC273F-220-R<br />
D148 Housing, rear extension NV273 1 99-08 AE TC271F-223-R<br />
TRANSFER CASE CHAINS<br />
B165 Chain, drive 98 links 1.500” wide (RP) NV273 1 99-08 F81Z-7A029-AA HV-064<br />
ELECTRICAL COMPONENTS<br />
D177 Motor, electric shift NV273 1 99-08 YC3Z-7G360-AA 600-805<br />
SHIFT FORKS AND PADS<br />
D190 Pad, fork (nylon) NV273 1 03-08 NV37284 TC261-28<br />
D191 Pad, fork (nylon) range (ends) 2 99-02 F81Z-7C430-BA 04167969<br />
D192 Pad, fork (nylon) range (center) 1 99-02 F81Z-7C430-DA 04338376<br />
D193 Fork, range shift (iron) stamped steel 1 99-02 IC3Z-7A082-BA TC241D-123<br />
D193 Fork, range shift NV273 1 03-08 n/a TC271D-123<br />
D195 Pad, fork (nylon) mode (ends) 1 99-08 04167969 04167969<br />
D197 Pad, fork (nylon) mode (center) 1 99-08 F81Z-7C430-EA 04219073<br />
D199 Fork, mode shift NV273 1 99-08 F81Z-7289-AA TC271-124<br />
NOTES<br />
NV273F<br />
© 2012 Autry Enterprises Ltd. 41
Dana 20F<br />
92<br />
85 40 88 90 91<br />
93<br />
44 45<br />
210<br />
47 49 48<br />
96<br />
51<br />
98<br />
Dana 20F<br />
A<br />
B<br />
56<br />
101<br />
intermediate<br />
gear<br />
110 66<br />
3<br />
112<br />
mainshaft<br />
gear<br />
rear<br />
output shaft<br />
sliding gear<br />
57 58 59 60 61 63<br />
68 69<br />
70 71<br />
115<br />
rear output<br />
shaft<br />
105 6 106<br />
intermediate<br />
shaft<br />
117<br />
speedo shims<br />
drive<br />
gear<br />
lock<br />
plate<br />
118<br />
73 74<br />
yoke<br />
nut<br />
C<br />
120<br />
nut<br />
19<br />
10<br />
yoke<br />
spacer<br />
front output<br />
shaft<br />
front<br />
gear<br />
output shaft<br />
sliding gear<br />
133<br />
front<br />
output shaft<br />
13<br />
143 144<br />
25<br />
D<br />
adapter<br />
housing<br />
23<br />
121<br />
11<br />
front bearing<br />
retainer<br />
20<br />
123 125 126<br />
1<br />
134<br />
shift rail<br />
190<br />
194<br />
pan<br />
front<br />
output shaft<br />
rear<br />
output shaft<br />
fork<br />
fork<br />
case<br />
137<br />
136<br />
fill<br />
plug<br />
detents<br />
140<br />
138<br />
79<br />
shims<br />
extension<br />
housing<br />
148<br />
cover<br />
35<br />
212<br />
speedo<br />
driven<br />
gear<br />
215<br />
Dana 20F<br />
TC20F<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal Dana 20 1 66-72 AE TK-20B<br />
n/i Kit, bearing/gasket/seal Dana 20 1 73-77 AE TK-20C<br />
n/i Kit, gasket/seal Dana 20 1 72-77 AE K105-918<br />
METAL CLAD SEALS<br />
D19 Seal, metal clad front input shaft 1 72-77 C6TZ-7B215-C 205-18676<br />
D23 Seal, metal clad front output shaft 1 72-77 D2TZ-7B2A5-B 205-15450<br />
D25 Seal, metal clad rear output shaft 1 72-74 D2TZ-7B215-B 205-15450<br />
D25 Seal, metal clad rear output shaft 1 75-77 D7TZ-7B215-A 205-15635<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A40 Bearing, ball .825” 3.145” od 1.378” id fron input shaft (front) 1 72-77 E1ZZ-7065A 6307N<br />
A44 Bearing, tapered (cup) rear output shaft (front) 1 72-77 n/a 25821<br />
A45 Bearing, tapered (cone) rear output shaft (front) 1 72-77 F6ZZ-7065-AA 25877<br />
A48 Bearing, tapered (cup) rear output shaft (rear) 1 72-77 n/a 25821<br />
A49 Bearing, tapered (cone) rear output shaft (rear) 1 72-77 F6ZZ-7065-AA 25877<br />
C69 Bearing, tapered (cup) front output shaft (front) 1 72-77 n/a 25821<br />
C70 Bearing, tapered (cone) front output shaft (front) 1 72-77 F6ZZ-7065-AA 25877<br />
C73 Bearing, tapered (cone) front output shaft (rear) 1 72-77 F6ZZ-7065-AA 25877<br />
C74 Bearing, tapered (cup) front output shaft (rear) 1 72-77 n/a 25821<br />
NOTES<br />
42 © 2012 Autry Enterprises Ltd.
<strong>Transfer</strong> <strong>Case</strong> Adapter Gaskets<br />
13590 13592A 13592<br />
<strong>Transfer</strong> <strong>Case</strong> Adapter Gaskets<br />
TRANSFER CASE ADAPTER GASKETS<br />
13591 13589 13593<br />
13595 13596 13594<br />
DESCRIPTION Qty Year PART #<br />
TRANSFER CASE ADAPTER GASKETS<br />
Gasket, transfer case adapter NP203 - CHEVROLET/GMC, DODGE 1 1969-79 13590<br />
Gasket, transfer case adapter NP205 - CHEVROLET/GMC, (w/o TH400) FORD, DODGE 1 1969-Up 13592<br />
Gasket, transfer case adapter NP205 - CHEVROLET/GMC, (w/TH400) 1 1979-Up 13592A<br />
Gasket, transfer case adapter NP203/NP205 - FORD (w/direct mounting) 1 1974-Up 13591<br />
Gasket, transfer case adapter NP208/NP241 - CHEVROLET/GMC 1 1980-Up 13589<br />
Gasket, transfer case adapter NP208/BW1345/BW1356 - AMC, DODGE, FORD 1 1980-Up 13593<br />
Gasket, transfer case adapter NP207/NP231 - CHEVY/GMC "S" SERIES w/TH700-R4 1 1983-Up 13595<br />
Gasket, transfer case adapter BW QUADRATRAC - JEEP (except CJ series) 1 1974-79 13596<br />
Gasket, transfer case adapter BW1350 - FORD 1 1980-Up 13594<br />
© 2012 Autry Enterprises Ltd. 43
Dana 21<br />
90<br />
92 93<br />
94<br />
45<br />
210<br />
47 49 96<br />
51<br />
98<br />
Dana-21<br />
A<br />
B<br />
mainshaft<br />
gear<br />
rear<br />
output shaft<br />
stationary<br />
gear<br />
56<br />
101<br />
intermediate<br />
gear<br />
rear output<br />
shaft<br />
57 58<br />
59 60 61 63<br />
speedo shims<br />
drive<br />
gear<br />
105 6 106<br />
intermediate<br />
shaft<br />
lock<br />
plate<br />
yoke<br />
nut<br />
110<br />
66<br />
3<br />
112<br />
68<br />
115<br />
70 114 71 117 73<br />
118<br />
C<br />
nut<br />
yoke<br />
spacer<br />
front output<br />
shaft<br />
gear<br />
front<br />
output shaft<br />
sliding<br />
gear<br />
front<br />
output shaft<br />
D<br />
119<br />
20<br />
22<br />
123<br />
170<br />
124<br />
indicator<br />
nut switch<br />
125<br />
126<br />
120<br />
130<br />
detent<br />
131 132<br />
10<br />
11<br />
140<br />
141 143<br />
144<br />
79<br />
shims<br />
13<br />
151<br />
148<br />
cover<br />
152<br />
25<br />
linkage<br />
front bearing<br />
retainer<br />
front<br />
output shaft<br />
fork<br />
shift rail<br />
190<br />
146<br />
1<br />
case<br />
pan<br />
145<br />
extension<br />
housing<br />
35<br />
212<br />
speedo<br />
driven<br />
gear<br />
215<br />
Dana 21<br />
TC21<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal Dana 21 1 74-76 TCRK-21 TK-21<br />
n/i Kit, gasket/seal Dana 21 1 74-76 DTK-21 K105-985<br />
METAL CLAD SEALS<br />
D20 Seal, metal clad shift shaft 2 74-76 6203 205-6203<br />
D22 Seal, metal clad front output shaft 1 74-76 15450 205-15450<br />
D25 Seal, metal clad rear output shaft 1 74-76 15699 205-15699<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A45 Bearing, tapered (cone) rear output shaft (front) 1 74-76 25877 25877<br />
A45 Bearing, tapered (cup) rear output shaft (front) 1 74-76 25821 25821<br />
A49 Bearing, tapered (cone) rear output shaft (rear) 1 74-76 25877 25877<br />
A49 Bearing, tapered (cup) rear output shaft (rear) 1 74-76 25821 25821<br />
C70 Bearing, tapered type (cup) front output shaft (front) 1 74-76 14131 14131<br />
C70 Bearing, tapered type (cone) front output shaft (front) 1 74-76 14276 14276<br />
C73 Bearing, tapered type (cone) front output shaft (rear) 1 74-76 14276 14276<br />
C73 Bearing, tapered type (cup) front output shaft (rear) 1 74-76 14131 14131<br />
44 © 2012 Autry Enterprises Ltd.
Dana 24<br />
105 65<br />
107 108 67<br />
110<br />
111 113<br />
69 115 70 72 120 210 121 74 123<br />
76 125<br />
A<br />
B<br />
nut<br />
front<br />
rear output<br />
speedo<br />
yoke<br />
input main drive<br />
yoke<br />
shaft gear rear output<br />
shaft<br />
drive<br />
gear<br />
sliding gear<br />
130 80 81<br />
132 133<br />
83 135<br />
nut<br />
idler<br />
idler shaft idler shaft<br />
shaft<br />
drive gear low speed<br />
gear<br />
141 90 142 144 91 93 145 147<br />
149<br />
95<br />
nut<br />
Dana 24<br />
C<br />
nut<br />
30<br />
yoke<br />
160 10<br />
high speed<br />
front<br />
gear<br />
output<br />
sliding gear<br />
front<br />
output shaft<br />
181<br />
15<br />
186<br />
57<br />
35<br />
D<br />
31<br />
input shaft<br />
bearing retainer<br />
168 12<br />
front<br />
output shaft<br />
bearing retainer<br />
165 11<br />
33<br />
195<br />
front<br />
output shaft<br />
fork<br />
170 171 173<br />
shift rail<br />
198<br />
rear<br />
output shaft<br />
fork<br />
180<br />
14<br />
cover<br />
case<br />
16 188<br />
extension<br />
housing<br />
bearing<br />
retainer<br />
20 189<br />
bearing<br />
retainer<br />
Dana 24<br />
TC24<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal Dana 24 1 62-72 TCRK-24 TK-24<br />
n/i Kit, gasket/seal Dana 24 1 62-72 DTK-24 K105-986<br />
NOTES<br />
© 2012 Autry Enterprises Ltd. 45
DanaModel-28<br />
DanaModel-28<br />
A<br />
B<br />
45<br />
75 76 78<br />
input<br />
shaft<br />
100<br />
nut<br />
79<br />
80<br />
drive<br />
sprocket<br />
101<br />
shield<br />
135<br />
drive chain<br />
15 64<br />
120<br />
140<br />
magnetic<br />
clutch<br />
assembly<br />
48<br />
5 103 57 106<br />
output shaft<br />
front<br />
85<br />
ring<br />
gear<br />
65<br />
50<br />
86<br />
planetary<br />
driven<br />
sprocket<br />
87 51 88 90<br />
reluctor<br />
wheel<br />
58<br />
107<br />
108 111<br />
123<br />
oil<br />
baffle<br />
speedo<br />
reluctor drive<br />
wheel gear<br />
91<br />
180 115<br />
54<br />
92 53 95 96<br />
output shaft<br />
rear<br />
145<br />
C<br />
16<br />
66<br />
35 18<br />
143<br />
speed<br />
sensor<br />
speed<br />
sensor<br />
front<br />
case half<br />
rear<br />
case half<br />
Dana 28<br />
TC28<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
REBUILDER KITS<br />
n/i Kit, bearing/gasket/seal Dana 28 1 90-97 AE TK-28<br />
n/i Kit, gasket/seal Dana 28 1 90-97 AE K105-917<br />
GASKETS AND RUBBER COMPONENTS<br />
n/i Gasket, adapter Dana 28 1 90-97 M353317A 13594<br />
METAL CLAD SEALS<br />
C15 Seal, metal clad front output shaft 1 90-97 F09Z-7B215-A 205-18623<br />
C16 Seal, metal clad front input shaft 1 90-97 F09Z-7B215-B 205-17353<br />
C18 Seal, metal clad rear output shaft 1 90-97 n/a 205-14978<br />
BUSHINGS<br />
C35 Bushing .935” 1.510” id 1.665” od extension housing 1 90-97 n/a TC28-162<br />
WASHERS/BEARINGS/RACES/SHIMS<br />
A45 Bearing, ball .747” 3.344” od 1.772” id front input shaft (front) 1 90-97 F09Z-7065-A 6209N<br />
A48 Bearing, caged .620” 1.311“ id 1.630” od input shaft (rear) 1 90-97 B-2110 TC28-135<br />
A54 Bearing, ball .747” 3.344” od 1.772” id rear output shaft (front) 1 90-97 F09Z-7025-A 6209N<br />
B57 Bearing, ball .590” 1.573” id 2.675” od front output shaft (front) 1 90-97 F09Z-7118-A 6008-J<br />
B58 Bearing, ball .747” 3.344” od 1.772” id front output shaft (middle) 1 90-97 F09Z-7025-A 6209N<br />
C65 Bearing, caged .620” 1.311“ id 1.630” od front output shaft (rear) 1 90-97 B-2110 TC28-135<br />
C66 Bearing, caged .620” 1.311“ id 1.630” od rear output shaft (rear) 1 90-97 B-2110 TC28-135<br />
HARD PARTS<br />
A75 Shaft, input Dana 28 1 90-97 F09Z-7017-A TC28-172-R<br />
A79 Gear, drive sprocket Dana 28 1 90-97 F09Z-7177-A TC28-175-R<br />
A85 Gear, ring Dana 28 1 90-97 F09Z-7A385-A TC28-178-R<br />
A86 Gear, planetary Dana 28 1 90-97 F09Z-7A398-A TC28-180-R<br />
A88 Gear, reluctor wheel 64T Dana 28 1 90-97 F09Z-7G450-A TC28-183-R<br />
A95 Shaft, rear output Dana 28 1 90-97 F09Z-7061-A TC28-187-R<br />
B100 Nut, front output shaft Dana 28 1 90-97 AE TC28-190-R<br />
B101 Shield, front output shaft Dana 28 1 90-97 F09Z-7C016-A TC28-191-R<br />
46 © 2012 Autry Enterprises Ltd.
DanaModel-28<br />
ILL DESCRIPTION QTY YEAR REFERENCE # PART #<br />
HARD PARTS (CONTINUED)<br />
B106 Shaft, front output Dana 28 1 90-91 F09z-7024-A TC28-194-R<br />
B106 Shaft, front output Dana 28 1 92-97 F29Z-7024-Z TC28-194A-R<br />
B108 Gear, driven sprocket Dana 28 1 90-97 F09Z-7177-B TC28-197-R<br />
B111 Gear, reluctor wheel 32T Dana 28 1 90-97 AE TC28-199-R<br />
C120 Housing, front case Dana 28 1 90-97 F59Z-7005-B TC28-203-R<br />
C123 Housing, rear case Dana 28 1 90-97 F79Z-7005-AB TC28-205-R<br />
TRANSFER CASE CHAINS<br />
A135 Chain, drive 86 links 1.250” wide (RP) Dana 28 1 90-97 F09Z-7A029-A HV-048<br />
ELECTRICAL COMPONENTS<br />
A140 Clutch, magnetic assembly Dana 28 1 90-97 F09Z-7G361-A TC28-260-R<br />
C143 Sensor, speed Dana 28 1 90-97 F09Z-7F293-A TC28-263-R<br />
C145 Sensor, speed Dana 28 1 90-97 F09Z-7F293-A TC28-264-R<br />
SPEEDO GEARS<br />
B180 Gear, speedo drive Dana 28 1 90-97 F09Z-17285-A TC28-270-R<br />
NOTES<br />
DanaModel-28<br />
© 2012 Autry Enterprises Ltd. 47
The Ultimate Engine Hanger<br />
T-1256<br />
48 © 2012 Autry Enterprises Ltd.