Overhaul (Transmission)

DISASSEMBLY





Position transfer case on shallow drain pan. Remove drain plug (3) and drain lubricant remaining in case.

SHIFT MOTOR ASSEMBLY





1. Remove the bolts (2) which hold the shift motor and mode sensor assembly (1) to the transfer case.





2. Remove the shift motor and mode sensor assembly (1) from the transfer case.





3. Remove and discard the shift motor O-ring (2) from the shift motor (1).





4. Remove the transfer case shift screw (1) and top bearing from the transfer case.





5. Remove the shift screw lower bearing (1) from the transfer case.

REAR CASE





1. Support transfer case so rear case is facing upward.
2. Remove bolts holding the front case (2) to the rear case (1).
3. Loosen rear case with flat blade screwdriver to break sealer bead.
4. Remove the rear case (1) from the front case (2).

DRIVE CHAIN AND SPROCKETS





1. Remove the shift fork (1) and sleeve (2) as an assembly.





2. Remove the front output shaft drive sprocket (1) retaining ring (2).





3. Remove the mainshaft drive sprocket (1) retaining ring (2).





4. Remove the front output shaft drive sprocket (1), the mainshaft drive sprocket (3), and the drive chain (2) as one unit.

FRONT OUTPUT SHAFT





1. Remove the front propeller shaft seal boot (1) retaining clamp (2).





2. Remove the front propeller shaft seal boot (2) from the front output shaft seal slinger (3).





3. Using a suitable hammer and chisel, strike the seal slinger (2) with the chisel as shown in three, equally spaced locations.





4. The indentations (2) should appear as shown here.





5. Remove the front output shaft seal slinger (1) from the output shaft (2).





6. Remove the front output shaft seal (1) from the transfer case bore (2) using a suitable tool.





7. Remove the front output shaft retaining ring (2) from the output shaft (1).





8. Remove the front output shaft (1) from the transfer case front case.

MAIN SHAFT





1. Remove the mainshaft assembly (1) from the input gear (2)





2. Remove the mainshaft thrust washer (1) from the input gear (2).





3. Remove the differential retaining ring (1) from the mainshaft.





4. Remove the differential assembly (1) from the mainshaft (2).

DIFFERENTIAL





1. Remove the mode hub and mode hub retainer (2) from the differential assembly (1).





2. Remove the mode hub retainer (1) from the mode hub (2).

INPUT GEAR





1. Remove the input gear assembly (2) retaining ring (1) from the transfer case.





2. Remove the input gear assembly (1) from the transfer case front case.

CLEANING
Clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases and retainers with a scraper and 3M all purpose cleaner. Use compressed air to remove solvent residue from oil feed passages in the case halves, retainers, gears, and shafts.

INSPECTION

MAINSHAFT AND SPROCKET INSPECTION
Inspect the splines on the shaft and the teeth on the sprocket. Minor nicks and scratches can be smoothed with an oilstone. However, replace any part that is damaged.

Check the contact surfaces in the sprocket bore and on the mainshaft. Minor nicks and scratches can be smoothed with 320-400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe.

INPUT GEAR AND BEARING ASSEMBLY
Check the teeth on the input gear. Minor nicks can be dressed off with an oilstone but replace the gear if any teeth are broken, cracked, or chipped. Check the bearing for smooth operation. Replace the input gear and bearing assembly if the bearing exhibits any sign of damage or rough rotation.

SHIFT FORK AND SLEEVE





Check condition of the shift fork and mode fork shift rail. Minor nicks on the shift rail can be smoothed with 320-400 grit emery cloth.

Inspect the shift fork wear pads (1). The mode fork pads are serviceable and can be replaced if necessary.

FRONT OUTPUT SHAFT AND DRIVE CHAIN
Inspect the sprocket teeth and bearing surfaces. Minor nicks on the teeth can be smoothed with an oilstone. Use 320-400 grit emery to smooth minor scratches on the shaft bearing surfaces. Replace the shaft if the splines are damaged, bearing surfaces are scored, or if any sprocket teeth are cracked or broken.

Examine the drive chain and shaft bearings. Replace the chain and both sprockets if the chain is stretched, distorted, or if any of the links bind. Replace the bearings if rough, or noisy.

FRONT/REAR CASES
Inspect the cases for wear and damage. Replace the input shaft seal; do not reuse it.

Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also make sure the front case mounting studs are in good condition.

Check the front case mounting studs and vent tube. The tube can be secured with Loctite(tm) 271 or 680 if loose. The stud threads can be cleaned up with a die if necessary. Also check condition of the fill/drain plug threads in the rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired with Helicoil stainless steel inserts if required.

ASSEMBLY
Lubricate transfer case components with Mopar ATF +4, Automatic Transmission Fluid or petroleum jelly (where indicated) during assembly.

BEARINGS





1. Remove the front output shaft bearing retaining ring from inside the front case (1) half.
2. Using Installer 6953 and Handle C-4171, remove front output shaft bearing.
3. Start the front output shaft bearing in case. Then seat bearing with Handle C-4171 (3) and Installer 6953 (2)
4. Install the front output shaft bearing retaining ring.





5. Remove the front output shaft rear bearing with the screw and jaws from Remover L-4454 (2) and Cup 8148 (3).





6. Install the new front output shaft rear bearing (2) with Tool Handle C-4171 (1) and Installer 5066 (3).

INPUT GEAR





1. Align and install the input gear and bearing assembly (1) into the front case. Be sure that the input gear bearing is fully seated in the front case.





2. Install snap-ring (2) to hold the input gear assembly (2) into the front case.
3. Install a new input shaft oil seal with Handle C-4171 and Installer 8841.

MAINSHAFT





1. Lubricate the mainshaft splines with recommended transmission fluid.

Note: Replace the mode hub retainer if the legs were distorted during removal.

2. Install the mode hub retainer (1) onto the mode hub (2).





3. Install the mode hub and mode hub retainer (2) onto the differential assembly (1). Make sure the retainer is fully seated onto the differential.





4. Install the differential assembly (1) onto the mainshaft (2).





5. Install the differential snap-ring (1).





6. Install the mainshaft thrust washer (1) onto the input gear assembly (2).





7. Install the mainshaft and differential assembly (1) into the input gear (2).

FRONT OUTPUT SHAFT





1. Install the front output shaft (1) into the transfer case front case.





2. Install the front output shaft retaining ring (2) onto the output shaft (1).





3. Install the new front output shaft seal (1) into position in the transfer case bore (2).
4. Install the new front output shaft seal (1) with Installer MB991168A.





5. Install the new front output shaft seal slinger (1) into position on the output shaft (2).
6. Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft.





7. Install the seal boot (2) onto the seal slinger (3)
8. Install a new seal boot clamp onto the seal boot.
9. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool C-4975-A.

DRIVE CHAIN AND SPROCKETS





1. Install the front output shaft drive sprocket (1), the mainshaft drive sprocket (3), and the drive chain (2) as one unit.





2. Install the mainshaft drive sprocket (1) retaining ring (2).





3. Install the shift fork (1) and sleeve (2) as an assembly.





4. Install the front drive sprocket (1) retaining ring (2).

REAR CASE





1. Install the magnet in the front case pocket.
2. Support transfer case so that the rear case is facing upward.
3. Apply 3 mm (1/8 inch) wide bead of Mopar Gasket Maker, or equivalent silicone adhesive sealer, to mounting flange of front case. Work sealer bead around bolt holes.
4. Install the rear case (1) onto the front case (2).
5. Install the bolts to hold the front case (2) to the rear case (1).
6. Tighten case bolts to 25 - 28 Nm (18 - 21 ft. lbs.) torque.

SHIFT MOTOR AND MODE SENSOR ASSEMBLY





1. Install the shift screw lower bearing (1) into the transfer case.





2. Make sure the bearing is installed with the tabs (1) up.





3. Install the shift screw top bearing (1) onto the shift screw (2). Make sure the bearing is installed with the tabs down.





4. Install the transfer case shift screw (1) and top bearing from the transfer case. Make sure that the shift screw is fully seated in the case. The missing tooth in the shift screw spines should be aligned with the indicator groove in the case.





5. Verify that the shift motor O-ring (2) is clean and properly positioned inside the machined O-ring groove of the shift motor (1).
6. Add high temperature grease between the shift motor assembly and the transfer case mating surface for sealing purposes.





Note: Verify that the missing tooth (2) in the shift motor drive spline (1)...





Note: ...and the transfer case drive spline (1) missing tooth (2) are aligned. It may be necessary to manually shift the transfer case if the shift motor and transfer case shaft are not aligned.





7. Position the shift motor and mode sensor assembly (1) onto the transfer case.





CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite(tm) 242 to replenish the lock patch material originally found on the bolts

8. Install the bolts (2) to hold the shift motor and mode sensor assembly (1) to the transfer case. Tighten the bolts to 9 - 14 Nm (7 - 10 ft. lbs.).

EXTENSION SEAL





1. Clean fluid residue from sealing surface and inspect for defects.
2. Using Installer D-163 (2) and Handle C-4171 (1), install the new seal into the rear case extension.