Part 1

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.




Figure 1 - MP3022 EXPLODED VIEW





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 font 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. Remove the rear output shaft bearing from the rear case using Installer (2) inverted and Handle (3).
8. Install the rear output shaft bearing into the rear case using Remover/Installer (2) inverted and Handle (3).





9. Remove shift shaft bearing snap ring.










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










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





12. Install shift shaft bearing snap ring.





13. Install the guide rails and the guide rail bolts. Tighten the guide rail bolts to 5-8 Nm (44-71 in.lbs.).










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





15. Install the front output shaft snap ring.





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





17. Install the input gear into the planetary gear.





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





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





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





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





22. Install the input gear snap ring.










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





24. Install the spring washers onto each side of the spring and install the spring assembly into the shift fork.
25. Install the shift bracket over the spring washers and onto the shift fork.