Rebuilding the T-Case Mechanical Shifter

Fig. 1

Shifter Parts

Fig. 2

Felt and O-Ring Installation

Fig. 3

Shift Shaft Installation

Fig. 4

Shift Fork Installation

Fig. 5

Fork Retainer Bolt Installation

Gather the parts shown in Fig. 1.You will also need a 12mm wrench and an adjustable wrench.
Use a dental pick to install the O-ring and the felt washer as shown in Fig. 2. Get the felt straight in the bore. This is actually a dust seal! Soak the felt with 90W oil.
Coat the shift shaft and shift fork with 90W. Insert the shift shaft into the housing as shown in Fig. 3. Rotate it so the hole is as shown then slide it back enough to insert the shift fork.
Place the shift fork over the shaft then slide the assembly forward and align the two holes as shown in Fig. 4.
Insert the shift fork retainer bolt with lock washer through the two holes and tighten it firmly. See Fig. 5.
Replace the large plug screw and washer. Tighten firmly.

Fig. 6

Detent Spring/Ball Installation

Fig. 7

Rubber Boot Installation

Place the detent ball and spring into the hole shown in Fig. 6 then insert the spring retainer bolt and washer and tighten firmly.
Install the rubber boot over the shift shaft and into the groove machined into the housing. See Fig. 7. If there is a hole in the boot make sure it is facing in the direction that 'down' will be. This allows any water that the boot may ingest to drain out.

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