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Transfer Case Actuator

Powertrain Management › Transmission Control Systems
Unified entry — merged from multiple cross-listed pages in the original manual.

Labor

Replace — Actuator Motor0.7 hr
Warranty 0.0 hrSkill B
Procedures
MP1522 Transfer Case — Shift Motor with Mode Sensor - Removal5 steps
ℹ NOTE
New shift motor assemblies are shipped in the NEUTRAL position. If a new shift motor assembly must be installed, it will be necessary to shift the transfer case to the NEUTRAL position prior to motor installation.
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  1. Raise the vehicle on a suitable hoist.
  2. Disengage the wiring connector from the shift motor and mode sensor assembly.
  3. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) onto the transfer case.
  4. Separate the shift motor and mode sensor assembly (1) from the transfer case (3) and shift sector (2). Figure 3 - SHIFT MOTOR SEAL RING
  5. Remove the seal ring (1) from the shift motor (2).
MP1522 Transfer Case — Shift Motor with Mode Sensor - Installation6 steps
ℹ NOTE
Verify that the missing tooth (2) in the shift motor drive spline (1).
ℹ 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.
△ CAUTION
If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock AND Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts
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  1. Install the seal ring (1) onto the shift motor (2).
  2. Verify that the shift motor o-ring is clean and properly positioned inside the machined o-ring groove of the shift motor.
  3. Position the shift motor and mode sensor assembly (1) onto the transfer case (3) and shift sector (2).
  4. Install the bolts (1) to hold the assembly (2) onto the transfer case. Tighten the bolts to 25-28 Nm (18.5-20.5 ft.lbs.).
  5. Engage the wiring connector to the shift motor and mode sensor assembly.
  6. Lower vehicle and verify transfer case operation.
MP3022 Transfer Case — Shift Motor - Installation4 steps
ℹ NOTE
Before installing the shift motor onto the transfer case, make certain that the shift motor shaft aligns with the transfer case worm shaft accordingly.
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  1. Install a NEW shift motor o-ring seal (2) onto the shift motor (1).
  2. Install the shift motor (1) onto the transfer case.
  3. Install the shift motor bolts. Tighten the shift motor bolts to 13 Nm (9 ft. lbs.).
  4. Install the electrical wiring harness connector onto the shift motor.
MP3022 Transfer Case — Shift Motor - Removal4 steps
ℹ NOTE
New shift motor assemblies are shipped in the NEUTRAL position. If a new shift motor assembly must be installed, it will be necessary to shift the transfer case to the NEUTRAL position prior to motor installation.
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  1. Disengage the wiring harness electrical connector from the shift motor.
  2. Remove the bolts holding the shift motor onto the transfer case.
  3. Remove the shift motor from the transfer case.
  4. Remove the o-ring seal from the shift motor.
MP1522 Transfer Case — Shift Motor with Mode Sensor - Descriptionreference
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DESCRIPTION Figure 1 - MP1522 TRANSFER CASE The shift motor (3) is an electromechanical device consisting of a DC permanent magnet motor, a gear train and an analog position sensor. The shift motors' overall function is to move and lock a gear that moves the range fork found in the transfer case. This allows the transfer case to be shifted electrically to multiple operating positions (4WD LOW, 4WD LOCK and 2WD). The operating current of the shift motor under stall conditions is 30 amps maximum at 72° F with 13.5 volts, at the motor leads.
MP3022 Transfer Case — Shift Motor - Operationreference
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OPERATION Figure 1 - MP3022 TRANSFER CASE Shifting in the transfer case occurs when a Pulse Width Modulated (PWM) voltage is supplied to the shift motor (1) by the Final Drive Control Module (FDCM). A linear analog position sensor (Encoder) (3) located on the rear transfer case housing, provides the FDCM with the motors' angular, rotational position. With this information, the FDCM continuously knows the motors' position, and therefore allows it to accurately control the motors' operation, including voltage polarity which is used to control motor direction. The electronically controlled wet clutch pack uses an electric motor to actuate an internal gear train, clutch cam, and low range barrel cam. The clutch cam actuates the clutch levers that apply normal force to the multi-disc wet clutch pack. The clutch disks are alternately splined to the front and rear outputs. When normal force is applied to this clutch pack, torque is transferred to equalize speed differences between front and rear axles.
MP3022 Transfer Case — Shift Motor - Descriptionreference
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DESCRIPTION Figure 1 - MP3022 TRANSFER CASE The shift motor (1) is an electromechanical device consisting of a DC permanent magnet motor and a position holding brake. The shift motors' overall function is to move and lock a gear that moves the range fork and clutch lever found in the transfer case. This allows the transfer case to be shifted electrically to multiple operating positions (4WD AUTO, 4WD LOW and 2WD. The operating current of the shift motor under stall conditions is 30 amps maximum at 72° F with 13.5 volts, at the motor leads.