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TRANSFER CASE MP1522

Factory FSM · 49 topics
MP1522 - SERVICE INFORMATION📷 1
—
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BRACKET📷 1
2 - LOCK PLATE 20 - SHIFT 38 - DRIVE
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FORK CHAINS📷 1
21 - 39 - SNAP 3 - THRUST WASHER FLANGE
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NUT📷 1
22 - O-    40 -
4 - INPUT GEAR (SHAFT)                                             RING       DRIVEN
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FLANGE RING
24 - 42 - 6 - PLANETARY GEAR DAMPER
BOLTS
25 - 43 - OIL
DAMPER
7 - RANGE SLEEVE TUBE O- (if
RING
equipped) 26 - CASE 44 - OIL 8 - MAINSHAFT
BOLTS TUBE 27 - FILL 45 - FRONT 9 - DRIVE SPROCKET
PLUG CASE 28 - REAR 46 - FRONT 10 - CLUTCH GEAR
COVER FLANGE
29 - 11 - HUB DRIVE SPROCKET 47 - STUDS
DOWEL
30 - ID 48 - SNAP 12 - SNAP RING TAG
SCREW
31 - ID 49 - INPUT 13 - SYNCHRONIZER HUB
TAG SEAL 32 - SHIFT 50 - VENT 14 - SNAP RING
DETENT TUBE
33 - SHIFT 51 - 15 - SYNCHRONIZER SLEEVE DETENT SPRING
SPRING CUP
34 - SHIFT 52 - 16 - OIL PUMP ASSEMBLY DETENT
BOLT
53 - SHIFT 35 - SHIFT 17 - SECTOR ROLLER RAIL
ANNULUS
18 - ROLL PIN 36 - BOLTS AND
RAILS
Command Trac® II with the new MP1522 two-speed, part-time four-wheel drive transfer case is the entry level four-wheel drive system. Functionally, the system performs the same way as other two-speed, part-time transfer cases. The most significant difference is electric shift, engaged with a console-mounted switch.
Command Trac® II is a part-time four-wheel drive system - 2WD High is the usual driving mode, with the front axle spinning freely and a power directed to the road rear wheels. Selecting 4WD High Lock, via the console- mounted switch, locks the front and rear driveshafts together; the two then rotate at the same and provide a 50
front/50 rear torque split. It is for use only on slippery or loose surfaces, such as snow or dirt. Driving on dry roads can result in driveline binding, resulting in undesirable driving dynamics and potential vehicle damage. It can be engaged at speeds under 55 MPH. A Neutral mode permits towing without having to disconnect the drive shafts. A pushpin button is provided to shift the transfer case into Neutral. For severe off-road situations, 4WD Low can be engaged at speeds of 2-3 MPH. The front and rear drive shafts are locked together, and a second gear set multiplies torque by 2.72:1, providing traditional Jeep capability.
The MP1522 transfer case provides the following benefits:
Electric shift operation, with a console-mounted switch that replaces the shift lever typical of systems with mechanical linkage. Command Trac® II with smooth operation and improved NVH control compared to systems with mechanical linkage. Traditional 2WD, 4WD Lock, Neutral and 4WD Low operation modes, and shift-on-the-fly capability. 4WD Low operation mode provides an advantage over vehicles equipped with a single-speed all-wheel drive transfer case. Enhanced traction and stability provided by the Traction Control and Electronic Stability Program (ESP) working in tandem with four-wheel drive, including Hill Start Assist, Hill Descent Control and Trailer Sway Control. Maintenance-free.
OPERATING RANGES
Transfer case operating ranges are:
Operating positions: 2WD - 4WD LOCK- N - 4WD LOW. 2WD - 2 Wheel Drive. 4WD LOCK- 4 High Part Time. N - Transfer case neutral for 4-wheel flat recreational towing. 4WD LOW- Low range (2.72:1) part time mode.
CONDITION POSSIBLE CAUSE CORRECTION
Transfer case difficult to shift or   1) Transfer case electronically    1) Verify proper operation per the
will not shift into desired range.    controlled shift system            appropriate diagnostic
                                      malfunction.                       information.
                                      2) Insufficient or incorrect       2) Drain and refill transfer case
                                      lubricant.                         with the correct quantity of
Mopar® ATF+4.
                                      3) Internal transfer case          3) Repair or replace components
                                      components binding, worn, or       as necessary.
damaged.
Transfer case noisy in all drive1) Insufficient or incorrect1) Drain and refill transfer case
modes.lubricant.with the correct quantity of
Mopar® ATF+4.
                                      2) Internal transfer case          2) Repair or replace components
                                      components binding, worn, or       as necessary.
damaged.
Transfer case noisy while in, or1) Transfer case not completely1) While rolling 2-3 MPH and the
jumps out of, 4WD LOW.engaged in 4WD LOW position.transmission in NEUTRAL shift
the transfer case to the 2WD or 4WD LOCK position, and then back into the 4WD LOW position. 2) Range fork, input gear, or range 2) Repair or replace components sleeve damaged, inserts worn, or as necessary. fork is binding on the shift rail.
                                      3) Low range gear worn or           3) Repair or replace components
                                      damaged.                            as necessary.
Lubricant leaking from transfer       1) Transfer case overfilled.        1) Drain lubricant to the correct
case seals or vent.                                                       level.
                                      2) Transfer case vent closed or     2) Clean or replace vent tube as
                                      restricted.                         necessary. Check for kink or
restriction in vent tube hose. 3) Transfer case seals damaged or 3) Replace suspect seals. Inspect installed incorrectly. and replace, if necessary, the seal slinger on the output flange associated with the damaged seal.
BRACKET📷 1
2 - LOCK PLATE 20 - SHIFT 38 - DRIVE
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FORK CHAINS📷 1
21 - 39 - SNAP 3 - THRUST WASHER FLANGE
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NUT📷 1
22 - O-    40 -
4 - INPUT GEAR (SHAFT)         RING       DRIVEN
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FLANGE RING📷 1
24 - 42 - 6 - PLANETARY GEAR DAMPER
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BOLTS📷 1
25 - 43 - OIL
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DAMPER📷 1
7 - RANGE SLEEVE TUBE O- (if
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RING📷 1
equipped) 8 - MAINSHAFT 26 - CASE 44 - OIL
BOLTS TUBE 27 - FILL 45 - FRONT 9 - DRIVE SPROCKET
PLUG CASE 28 - REAR 46 - FRONT 10 - CLUTCH GEAR
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COVER FLANGE📷 1
29 - 11 - HUB DRIVE SPROCKET 47 - STUDS
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DOWEL📷 1
30 - ID 48 - SNAP 12 - SNAP RING TAG
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SCREW📷 1
31 - ID 49 - INPUT 13 - SYNCHRONIZER HUB
TAG SEAL 32 - SHIFT 50 - VENT 14 - SNAP RING
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DETENT TUBE📷 1
33 - SHIFT 51 - 15 - SYNCHRONIZER SLEEVE DETENT SPRING
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SPRING CUP📷 1
34 - SHIFT 52 - 16 - OIL PUMP ASSEMBLY DETENT
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BOLT📷 1
53 - SHIFT 35 - SHIFT 17 - SECTOR ROLLER RAIL
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ANNULUS📷 1
18 - ROLL PIN 36 - BOLTS AND
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RAILS📷 37
1 - DETENT ASSEMBLY 2 - DRAIN PLUG 3 - SHIFT MOTOR/MODE SENSOR 4 - FILL PLUG 5 - DAMPER (if equipped) 6 - REAR FLANGE 7 - REAR FLANGE NUT
1. Place the transfer case in a shallow pan and remove the fill (4) and drain (2) plugs to drain the remainder of the fluid.
1 - HOLDER C-3281 2 - REAR OUTPUT FLANGE
2. Using Holder C-3281 (1), remove the rear flange (2) nut. 3. Remove the rear output flange (2) from the main shaft. If necessary, use a suitable 2 or 3 jaw puller to remove the output flange.
1 - FLANGE O-RING 2 - REAR OUTPUT FLANGE
4. Remove the rear output flange o-ring from the rear output flange.
1 - BOLTS 2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
5. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) to the transfer case.
1 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY 2 - SHIFT SECTOR 3 - TRANSFER CASE
6. Remove the shift motor and mode sensor assembly (1) from the shift rail (2) and the transfer case (3).
1 - SEAL RING 2 - SHIFT MOTOR
7. Remove the seal ring (1) from the shift motor (2).
1 - DAMPER 2 - BOLTS
8. Remove damper bolts (2) and damper (1), (if equipped).
1 - REAR HOUSING 2 - REAR COVER 3 - REAR COVER BOLTS
9. Remove the bolts (3) holding the rear cover (2) onto the rear housing (1).
1 - REAR COVER 2 - REAR HOUSING
NOTE: Use the pry slots provided and take care not to damage the sealing surface.
10. Remove the rear cover (1) from the rear housing (2).
1 - DETENT ASSEMBLY 2 - REAR CASE
11. Remove the detent assembly (1) from the rear housing (2).
1 - REAR HOUSING 2 - ROLL-PIN 3 - SHIFT RAIL 4 - SECTOR ROLLER
NOTE: Rotate the sector downward to ease the removal of the roll-pin.
12. Using a suitable punch, remove the roll-pin (2) holding the sector roller (4) to the shift rail (3).
1 - SECTOR ROLLER 2 - SHIFT RAIL
13. Remove the sector roller (1) from the shift rail (2).
1 - ANTI-ROTATION BRACKET 2 - SHIFT RAIL
14. Remove the anti-rotation bracket (1) from the shift rail (2).
1 - REAR HOUSING 2 - BOLTS 3 - FRONT HOUSING
15. Remove the bolts (2) holding the rear housing (1) to the front housing (3).
1 - REAR HOUSING 2 - FRONT HOUSING
NOTE: Some prying may be necessary to break the seal between the front and rear case. Use care to not damage the sealing surfaces.
16. Remove the rear housing (1) from the front housing (2).
1 - SHIFT SECTOR 2 - RETAINING RING
17. Remove the retaining ring (2) from the shift sector shaft (1).
1 - FRONT HOUSING 2 - SHIFT SECTOR
18. Remove the sector shaft (2) from the rear housing (1).
1 - OIL PUMP TUBE 2 - OIL PUMP
19. Remove the oil pump (2) and oil pump tube (1) from the mainshaft.
1 - OIL TUBE 2 - O-RING SEAL
20. Remove the o-ring seal (2) from the oil tube (1).
21. Remove the magnet.
1 - SHIFT FORK 2 - SYNCHRONIZER SLEEVE
22. Remove the shift fork (1) and synchronizer sleeve (2).
1 - SNAP RING 2 - SYNCHRONIZER HUB
23. Remove the synchronizer hub snap ring (1).
1 - SYNCHRONIZER HUB
24. Remove the synchronizer hub (1).
1 - HUB DRIVE AND CLUTCH GEAR
25. Remove the hub drive and clutch gear (1).
1 - FRONT OUTPUT SHAFT 2 - RETAINING RING
26. Remove the front drive sprocket retaining ring (2) from the front output shaft (1).
1 - FRONT DRIVE SPROCKET 2 - MAINSHAFT DRIVE SPROCKET 3 - DRIVE CHAIN
27. Remove the front drive sprocket (1), mainshaft drive sprocket (2), and drive chain (3) as one.
1 - CHAIN GUIDE RAIL 2 - SCREWS
28. Remove the screws (2) holding the both chain guide rails (1) to the front housing.
1 - DRIVE CHAIN GUIDE
29. Remove both drive chain guides (1) from the transfer case.
1 - MAIN SHAFT
30. Remove the mainshaft (1).
1 - SHIFT RAIL 2 - RANGE SLEEVE
31. Remove the shift rail (1) and range sleeve (2).
1 - SHIFT RAIL SPRING 2 - SHIFT RAIL SPRING SEAT
32. Remove the shift rail spring (1) and seat (2).
1 - FRONT OUTPUT SHAFT 2 - RETAINING RING
33. Remove the retaining snap ring (2) from the front output shaft (1).
1 - FRONT HOUSING 2 - FRONT OUTPUT SHAFT
34. Remove the front output shaft (2) from the front housing (1) and the front output shaft front bearing.
1 - INPUT GEAR 2 - RETAINING RING
35. Remove the input shaft seal with a suitable pry tool or a screw mounted in a slide hammer. 36. Remove the retaining ring (2) holding the input gear (1) assembly into the front housing.
1 - INPUT PLANETARY GEAR ASSEMBLY
37. Remove the input planetary gear assembly (1) from the front housing.
1 - INPUT GEAR SNAP-RING
38. Remove the snap-ring (1) holding the input gear into the planetary gear.
1 - INPUT GEAR 2 - PLANETARY GEAR 3 - RETAINER
39. Remove the input gear lock plate (3) from the planetary gear (2).
1 - INPUT GEAR 2 - LOW RANGE GEAR
40. Remove the input gear (1) from the planetary gear (2).
1 - PLANETARY GEAR 2 - REAR TABBED THRUST WASHER
41. Remove the rear tabbed thrust washer (1) from the planetary gear (2).
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BRACKET📷 1
2 - LOCK PLATE 20 - SHIFT 38 - DRIVE
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FORK CHAINS📷 1
21 - 39 - SNAP 3 - THRUST WASHER FLANGE
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NUT
22 - O-    40 -
4 - INPUT GEAR (SHAFT)                                         RING       DRIVEN
FLANGE RING
24 - 42 - 6 - PLANETARY GEAR DAMPER
BOLTS
25 - 43 - OIL
DAMPER
7 - RANGE SLEEVE TUBE O- (if
RING
equipped) 26 - CASE 44 - OIL 8 - MAINSHAFT
BOLTS TUBE 27 - FILL 45 - FRONT 9 - DRIVE SPROCKET
PLUG CASE 28 - REAR 46 - FRONT 10 - CLUTCH GEAR
COVER FLANGE
29 - 11 - HUB DRIVE SPROCKET 47 - STUDS
DOWEL
30 - ID 48 - SNAP 12 - SNAP RING TAG
SCREW
31 - ID 49 - INPUT 13 - SYNCHRONIZER HUB
TAG SEAL 32 - SHIFT 50 - VENT 14 - SNAP RING
DETENT TUBE
33 - SHIFT 51 - 15 - SYNCHRONIZER SLEEVE DETENT SPRING
SPRING CUP
34 - SHIFT 52 - 16 - OIL PUMP ASSEMBLY DETENT
BOLT
53 - SHIFT 35 - SHIFT 17 - SECTOR ROLLER RAIL
ANNULUS
18 - ROLL PIN 36 - BOLTS AND
RAILS📷 45
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.
NOTE: Lubricate all seals with MOPAR® ATF+4 prior to installation.
1 - INPUT GEAR BEARING 2 - FRONT CASE
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.
1 - FRONT CASE 2 - INSTALLER 6061 (INVERTED) 3 - HANDLE C-4171
3. Remove the front output shaft seal with a suitable pry tool or a screw mounted in a slide hammer. 4. Using inverted Installer 6061 and Handle C-4171, remove front output shaft bearing. 5. Start front output shaft bearing in case. Then seat bearing with Handle C-4171 (3) and inverted Installer 6061 (2). 6. Using Handle C-4171 (1) and Installer 6560 (2) install the front output shaft seal (3).
1 - HANDLE C-4171 2 - INSTALLER C-4210 3 - REAR OUTPUT SHAFT SEAL
7. Remove the rear output shaft seal with a suitable pry tool or a screw mounted in a slide hammer. 8. Install a new rear output shaft seal (3) into the rear cover using handle C-4171 (1) and Installer C-4210 (2).
1 - HANDLE C-4171 2 - INSTALLER 6436 (INVERTED)
9. Remove the rear output shaft bearing from the rear case using inverted Installer 6436 (2) and Handle C- 4171 (1). 10. Install the rear output shaft bearing into the rear case using inverted Remover/Installer 6436 (2) and Handle C-4171 (1).
1 - PLANETARY GEAR 2 - REAR TABBED THRUST WASHER
NOTE: The tabbed side of the thrust washer faces upward.
11. Install the rear tabbed thrust washer (2) into the planetary gear (1).
1 - INPUT GEAR 2 - LOW RANGE GEAR
12. Install the input gear (1) into the planetary gear (2).
1 - INPUT GEAR 2 - PLANETARY GEAR 3 - RETAINER
13. Install the input gear lock plate (3) onto the planetary gear (2) and install it into the planetary.
1 - INPUT GEAR SNAP-RING
14. Install the snap-ring (1) to hold the input gear into the planetary gear.
1 - INPUT PLANETARY GEAR ASSEMBLY
15. Install the input planetary gear assembly (1) into the front housing.
1 - INPUT GEAR 2 - RETAINING RING
16. Install the retaining ring (2) holding the input planetary gear assembly into the front housing. 17. Install the new input shaft seal with Installer 9672 and Handle C-4171.
1 - FRONT HOUSING 2 - FRONT OUTPUT SHAFT
18. Install a new front output shaft seal with Installer 6560. 19. Install the front output shaft (2) into the front housing (1) and the front output shaft front bearing.
1 - FRONT OUTPUT SHAFT 2 - RETAINING RING
20. Install the retaining ring (2) onto the front output shaft (1).
1 - SHIFT RAIL SPRING 2 - SHIFT RAIL SPRING SEAT
21. Install the shift rail spring cup (2) and shift rail spring (1).
1 - SHIFT RAIL 2 - RANGE SLEEVE
22. Install the shift rail (1) and range sleeve (2).
1 - MAIN SHAFT
23. Install the mainshaft (1).
1 - DRIVE CHAIN GUIDE
24. Install the both drive chain guides (1) onto the transfer case.
1 - CHAIN GUIDE RAIL 2 - SCREWS
25. Install the screws (2) to hold the chain guide rails (1) to the front housing. Tighten the screws to 5-8 N.m (44-71 in. lbs.).
1 - FRONT DRIVE SPROCKET 2 - MAINSHAFT DRIVE SPROCKET 3 - DRIVE CHAIN
CAUTION: Be careful not to damage the ground surface of the mainshaft while installing the sprockets and drive chain. Failure to follow this caution may result in transfer case damage.
26. Install the front drive sprocket (1), mainshaft drive sprocket (2), and drive chain (3) as one.
1 - FRONT OUTPUT SHAFT
2 - RETAINING RING
27. Install the front drive sprocket retaining ring (2) onto the front output shaft (1).
1 - HUB DRIVE AND CLUTCH GEAR
28. Install the hub drive and clutch gear assembly (1) onto the mainshaft.
1 - SYNCHRONIZER HUB
29. Install the synchronizer hub (1) onto the mainshaft.
1 - SNAP RING 2 - SYNCHRONIZER HUB
30. Install the synchronizer hub snap ring (1) onto the mainshaft.
1 - SHIFT FORK 2 - SYNCHRONIZER SLEEVE
31. Install the shift fork (1) and synchronizer sleeve (2) onto the shift rail and mainshaft.
32. Clean and install the magnet into the pocket.
1 - OIL TUBE 2 - O-RING SEAL
33. Install a NEW o-ring seal (2) onto the oil tube (1).
1 - OIL PUMP TUBE 2 - OIL PUMP
34. Lubricate the oil tube o-ring with MOPAR® ATF+4 and install the tube into the oil pump. 35. Install the oil pump (2) onto the mainshaft while installing the oil pump pick-up into the pocket in the case.
1 - FRONT HOUSING 2 - SHIFT SECTOR
36. Install the sector shaft (2) into the rear housing (1).
1 - SHIFT SECTOR 2 - RETAINING RING
37. Install the retaining ring (2) onto the shift sector shaft (1).
1 - REAR HOUSING 2 - FRONT HOUSING
38. Apply bead of Mopar® Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3 mm (0.125 inch). Do not use excessive amount of sealer as excess will be displaced into case interior and potentially clog the oil pump screen. 39. Install the rear housing (1) into the front housing (2).
NOTE: Use an alignment dowel (2) in the combination of the front (1) and the rear housing (3).
1 - FRONT CASE 2 - ALIGNMENT DOWEL 3 - REAR CASE
1 - REAR HOUSING 2 - BOLTS 3 - FRONT HOUSING
40. Install the bolts (2) to hold the rear housing (1) to the front housing (3). Tighten the bolts at the dowel locations first, then the remainder of the bolts in a crisscross pattern. Tighten the bolts to 27 N.m (20 ft. lbs.).
1 - ANTI-ROTATION BRACKET 2 - SHIFT RAIL
41. Install the anti-rotation bracket (1) onto the shift rail (2).
1 - SECTOR ROLLER 2 - SHIFT RAIL
42. Install the sector roller (1) onto the shift rail (2). 43. Using a suitable punch, align the holes in the sector roller with the hole in the shift rail and install the roll- pin to secure the sector roller to the shift rail.
1 - DETENT ASSEMBLY 2 - REAR CASE
44. Install the detent assembly (1) into the rear case (2). Tighten the bolt to 20 N.m (15 ft. lbs.).
1 - REAR HOUSING 2 - SEALANT
45. Apply bead of Mopar® Gasket Maker, or equivalent, to mating surface of rear housing as shown in graphic (2). Keep sealer bead width to maximum of 3 mm (1/8 inch).Do not use excessive amount of sealer as excess will be displaced into case interior and potentially clog the oil pump screen.
1 - REAR COVER 2 - REAR HOUSING
46. Install the rear cover (1) onto the rear housing (2).
1 - REAR HOUSING 2 - REAR COVER 3 - REAR COVER BOLTS
47. Install the bolts (3) holding the rear cover (2) onto the rear housing (1). Tighten the bolts at the dowel locations first, then the remainder of the bolts in a crisscross pattern. Tighten the bolts to 27 N.m (20 ft. lbs.).
1 - SEAL RING 2 - SHIFT MOTOR
48. Install the seal ring (1) onto the shift motor (2).
NOTE: Verify that the missing tooth (2) in the shift motor drive spline (1) .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.
1 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY 2 - SHIFT SECTOR 3 - TRANSFER CASE
49. Install the shift motor and mode sensor assembly (1) onto the shift sector (2) and the transfer case (3).
1 - BOLTS 2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
50. Install the bolts (1) to hold the shift motor and mode sensor assembly (2) to the transfer case. Tighten the bolts to 27 N.m (20 ft. lbs.).
1 - DAMPER 2 - BOLTS
51. Install the damper (1), (if equipped), and bolts (2) onto the case. Tighten the bolts to 27 N.m (20 ft. lbs.).
1 - FLANGE O-RING 2 - REAR OUTPUT FLANGE
52. Install the o-ring into the rear output flange.
1 - HOLDER C-3281 2 - REAR OUTPUT FLANGE
53. Install the rear output flange onto the main shaft. 54. Using Holder C-3281 (1), install the rear output flange (2) nut. Tighten the bolts to 122-176 N.m (90-130 ft. lbs.).
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MODE SENSOR VOLTAGES📷 1
Transfer Case Position                                              Voltage
              4WD LOW                                                     3.298 - 3.440
                Neutral                                                   2.729 - 2.871
              4WD Lock                                                    2.159 - 2.301
                 2WD                                                      1.599 - 1.741
SWITCH-TRANSFER CASE SELECTOR
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