MP3023 Transfer Case - Assembly

ASSEMBLY

Special Tools:



















NOTE: If the transfer case assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the Scan Tool.

NOTE: Lubricate all seals with MOPAR(R) ATF+4 prior to installation.

CAUTION: The bearing bores in various transfer case components contain oil feed holes. Be certain the holes are not blocked. Failure to follow this caution may result in transfer case damage.





1. While holding the retaining ring tabs apart with suitable snap-ring pliers, remove the input shaft bearing (1) from the front case (2).
2. Transfer the retaining ring to the new housing, if necessary, and install the bearing into the front case.





3. Using a suitable pry tool or a screw mounted in a slide hammer, remove the front output shaft seal.
4. Using Installer inverted, and Handle , remove front output shaft bearing.
5. Start front output shaft bearing in case. Then seat bearing with Handle (3) and Installer (2).
6. Install the front output shaft seal using Installer.





7. Using a suitable pry tool or a screw mounted in a slide hammer, remove the rear output shaft seal.
8. Remove the rear output shaft bearing from the rear case using Installer (2) inverted and Handle (1).
9. Install the rear output shaft bearing into the rear case using Remover/Installer inverted and Handle.





10. Remove shift shaft bearing snap ring.





11. Remove shift shaft bearing using Handle (1) and Installer / Remove (2).





12. Install shift shaft bearing using Handle and Installer / Remover inverted.





13. Install shift shaft bearing snap ring.





14. Remove front output shaft rear bearing from housing using Puller (1) and Slide Hammer (2).





15. Install front output shaft rear bearing in housing using Installer (2) inverted and Handle (2).





16. Install the front output shaft flange (2) into the front housing (1).





17. Install the front output shaft snap ring.





18. Install the bottom thrust tabbed washer into the planetary gear.





19. Install the input gear into the planetary gear.





20. Install the thrust washer onto the input planetary gear assembly.





21. Install the lock plate onto the input planetary gear assembly.





22. Install the snap ring into the input planetary gear assembly.





23. Install the input planetary gear assembly into the front housing.





24. Install the input gear snap ring.





25. Using Installer (2) and Handle (1), install a new input shaft seal.





26. Install the spring washers onto each side of the spring and install the spring assembly into the shift fork.
27. Install the shift bracket over the spring washers and onto the shift fork.
28. Install the range sleeve into the shift fork.
29. Install the range shift assembly and range sleeve.





30. Install the detent assembly.





31. Install the mainshaft into the transfer case.





32. Install the shift shaft.

NOTE: Before installing the barrel cam, note the orientation of the inner barrel cam splines to the outer splines on the shift shaft.





33. Install the barrel cam.





34. Install the shift shaft spacer.






NOTE: There is a blue link on one side of the chain. This blue link MUST be installed facing upward.

35. Install the front drive sprocket, mainshaft drive sprocket and drive chain as one.





36. Install the outer clutch drum onto the mainshaft drive sprocket.





37. Install the clutch drum snap ring (2) and thrust washer (1).





38. Install the inner clutch hub.





39. Starting with a friction disc and ending with a friction disc, install the clutch pack.





40. Install the clutch return springs.





41. Install the clutch apply piston with the lettering up and the stepped face down.





42. Install the lower bearing race with the race fitting into the grove in the reaction plate.





43. Install the lower bearing.





44. Install the lower shift lever.





45. Install the shift lever balls into their pockets.





46. Install the upper shift lever.





47. Install the upper thrust bearing.





48. Install the upper bearing race.





49. Install the thrust collar.





50. Install the clutch shim.





51. Install clutch upper snap ring.

NOTE: The clutch cam has the word "FRONT" stamped into. This identifies the orientation of the clutch cam to the front of the transfer case. Before installing the clutch cam, note the orientation of the clutch cam inner splines to the outer splines on the shift shaft. Install it such that the roller falls into low point of clutch cam.





52. Install the clutch cam.

NOTE: Before installing the worm drive gear, note the orientation of the worm drive gear inner splines to the outer splines on the shift shaft.





53. Install the worm drive gear.





54. Install the magnet into the magnet pocket.










55. Install a new o-ring (2) onto the oil pump tube (1).





56. Lubricate the oil tube o-ring with MOPAR(R) ATF+4 and install the tube into the oil pump.
57. Install the oil pump assembly.





58. install the output shaft thrust washer.






NOTE: Do not use excessive amount of sealer as excess could be displaced into the oil pump. Keep sealer bead width to maximum of 3 mm (1/8 inch).

59. Apply bead of Mopar(R) Gasket Maker, or equivalent, to one of the mating surfaces of the front or rear housing.
60. Install the rear housing onto the front housing. Install the housing bolts. Tighten housing bolts in a crisscross pattern to 27 Nm (20 ft.lbs.).

CAUTION: Carefully align and thread (rotate counterclockwise) the worm shaft to install it into the transfer case. Failure to follow this caution may result in parts damage.





61. Install the worm shaft into the transfer case.

NOTE: It may be necessary to apply slight inward pressure on the worm shaft to seat the snap ring.





62. Install the worm shaft snap ring.





63. Using a suitable installer, install the shift motor seal.





64. Install a new o-ring onto the shift motor.






NOTE: Note the orientation of the shift motor shaft to the worm gear shaft.

65. Install the shift motor onto the transfer case. Install the shift motor bolts. Tighten the shift motor bolts to 13 Nm (9 ft. lbs.).






NOTE: It may be necessary to pull out on the shift shaft to properly seat the shift shaft snap ring.

66. Install the shift shaft snap ring.





67. Align arrow (1) on the encoder shaft with alignment mark (2) prior to installing the encoder.

NOTE: Before installing the encoder onto the transfer case, be certain to align the encoder shaft to the shift shaft and the dowel on the encoder to the hole in the case accordingly.





68. Install the encoder onto the rear transfer case housing. Install the encoder screws. Tighten the screws to 5-8 Nm (44-71 in.lbs.).





69. Using a suitable pry tool or a screw mounted in a slide hammer, remove the rear cover seal.
70. Using Installer (2) and Handle (1), install the rear cover seal.





71. Install the companion flange onto the mainshaft.





72. Using Holder (1), install the rear output flange (2) nut. Tighten the nut to 122-176 Nm (90-130 ft.lbs.).