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TRANSFER CASE MP3022

Factory FSM · 79 topics
MP3022 - SERVICE INFORMATION📷 1
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GEAR📷 1
2 - INPUT BEARING 26 - SHIFT 50 - FRONT
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SNAP RING BEARING📷 1
27 - SHIFT   51- OUTPUT
3 - INPUT BEARING HOUDINI RING                            SHAFT        SHAFT GEAR
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BEARING SNAP RING📷 1
4 - CARRIER SNAP RING 28 - FLANGE 52- OUTPUT
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NUT SHAFT GEAR
29 - FLANGE 53 - SHIFT 5 - CARRIER LOCK PLATE
O-RING BRACKET
30 - 54 - OIL PUMP 6 - THRUST WASHER COMPANION
FLANGE 31 -
COMPANION 55 - DRIVE 7 - INPUT GEAR (SHAFT)
SLINGER
56 - FRONT 32 - DAMPER
OUTPUT
8 - TABBED THRUST WASHER BOLTS (if
SHAFT SNAP equipped)
RING
33 - DAMPER 57 - CHAIN 9 - PLANETARY GEAR ASSEMBLY (if equipped) GUIDE RAILS
                                     34 - REAR     58 - CHAIN
10 - SHIFT FORK                      COVER         GUIDE RAIL
BOLTS BOLTS
35 - OUTPUT 11 - SHIFT RAIL SPRING AND WASHERS 59 - MAGNET
BEARING
37 -          61 -
13 - RANGE SLEEVE                    ENCODER ALIGNMENT
BOLTS DOWEL
38 - SHIFT 14 - SHIFT RAIL MOTOR 62 - DETENT
BOLTS
39 - SHIFT 63 - DETENT 15 - MAIN SHAFT CLUTCH ASSEMBLY
ENCODER BOLT
65 - FRONT 41- SHIFT 17 - CLUTCH ASSEMBLY OUTPUT
SLINGER
43 - SHIFT    67 - INPUT
19 - BARREL CAM                      SHAFT SNAP SHAFT SNAP
RING RING 44 - WORM
SHAFT
68 - INPUT 20 - SHIFT SHAFT BEARING
CLIP 45 - WORM
SHAFT, 69 - FRONT
21 - OIL TUBE O-RING BEARING, OUTPUT
AND E-CLIP
70 - 22 - OIL PUMP 46 - ID TAG ATTACHMENT
STUDS 47 - REAR
OUTPUT
23 - SHIFT SHAFT SPACER -
BEARING
48 - FILL 24 - CLUTCH CAM AND DRAIN -
PLUG
The Select-Trac® II is the MP3022 two-speed, on-demand, active four-wheel drive transfer case that provides optimum traction for a wide range of conditions, while maximizing driver convenience. When operating in 4WD Auto mode, this sophisticated system anticipates and prevents slip by redirecting torque as necessary, up to 100 percent to either the front or rear axle if needed.
For added traction capability when traversing steep grades, rough terrain or extremely poor traction surfaces, the transfer case includes a 4WD Low mode. This second speed gear multiplies engine torque 2.72 times and locks the clutch pack for maximum traction.
Electric shifting between 4WD AUTO and 4WD Low is effected with a console-mounted switch. A pushpin button is used to shift to Neutral mode.
The MP3022 transfer case provides the following benefits:
Active, on-demand four-wheel drive requires no driver input. Instantly anticipates slip and preemptively redirects torque as needed. Vehicle stability under all conditions because torque is constantly being transferred. 4WD Low operation mode provides an advantage over vehicles equipped with a single-speed all-wheel drive transfer case. Electric shifting between 4WD Auto and 4WD Low provides smooth operation and improved NVH control compared to systems with mechanical linkage. Enhanced traction and stability provided by the Traction Control and Electronic Stability Program (ESP) working in tandem with four-wheel-drive. A robust design and sealing for reliability. Maintenance-free. A neutral mode permits flat towing.
OPERATING RANGES
Transfer case operating ranges are:
Operating positions: 2WD - 4WD Auto - N - 4WD Low. 2WD = 2 wheel drive. 4WD Auto = Electronically controlled wet clutch for torque biasing. N = Transfer case neutral for 4-wheel flat recreational towing. 4WD Low = Low range (2.72:1) part time mode.
The 4WD Low range is for off road use only. It is not for use on hard surface roads unless the road surface is wet, slippery, or covered by ice and snow.
The low range reduction gear system is operative in 4WD Low range only. This range is for extra pulling power in off road situations. Low range reduction ratio is 2.72:1.
ACTIVE TRANSFER CASE CONTROLS
Controls for the MP3022 transfer case active clutch (torque biasing device) are located in the Final Drive Control Module (FDCM) and communicated on the Controller Area Network (CAN) C bus. The FDCM monitors multiple vehicle sensors to anticipate conditions which may result in wheel slip or reduced performance and preemptively adjusts torque split to front and rear axles as needed. The FDCM also compares wheel speeds at the front and rear axles to detect wheel slippage. A complete vehicle dynamics model, or algorithm, calculates slip at each tire for given vehicle-operating conditions. When wheel slip is detected, pressure applied to the transfer case clutch pack can be increased or decreased to apply increased torque to the axle with higher traction.
TRANSFER CASE MODES
The transfer case operates in active full-time four-wheel drive (4WD AUTO) unless the driver chooses 4WD Low, 2WD or Neutral.
ELECTRONIC STABILITY PROGRAM (ESP)
Standard Electronic Stability Program (ESP) works with the four-wheel drive system to enhance traction and control through three new features: Hill Descent, Hill Start Assist and Trailer Sway Control.
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, 4LO.engaged in 4LOW position.transmission in NEUTRAL shift
the transfer case to the 4WD AUTO position, and then back into the 4LOW 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 as
                                      restricted.                         necessary.
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.
GEAR📷 1
2 - INPUT BEARING 26 - SHIFT 50 - FRONT
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SNAP RING BEARING📷 1
27 - SHIFT  51- OUTPUT
3 - INPUT BEARING HOUDINI RING   SHAFT       SHAFT GEAR
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BEARING SNAP RING📷 1
28 - FLANGE 52- OUTPUT 4 - CARRIER SNAP RING
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NUT SHAFT GEAR📷 1
29 - FLANGE 53 - SHIFT 5 - CARRIER LOCK PLATE
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O-RING BRACKET📷 1
30 - 54 - OIL PUMP 6 - THRUST WASHER COMPANION
FLANGE 31 -
COMPANION 55 - DRIVE 7 - INPUT GEAR (SHAFT)
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SLINGER📷 1
56 - FRONT 32 - DAMPER
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OUTPUT
8 - TABBED THRUST WASHER BOLTS (if
SHAFT SNAP equipped)
RING
33 - DAMPER 57 - CHAIN 9 - PLANETARY GEAR ASSEMBLY (if equipped) GUIDE RAILS
                                     34 - REAR     58 - CHAIN
10 - SHIFT FORK                      COVER         GUIDE RAIL
BOLTS BOLTS
35 - OUTPUT 11 - SHIFT RAIL SPRING AND WASHERS 59 - MAGNET
BEARING
37 -          61 -
13 - RANGE SLEEVE                    ENCODER ALIGNMENT
BOLTS DOWEL
38 - SHIFT 14 - SHIFT RAIL MOTOR 62 - DETENT
BOLTS
39 - SHIFT 63 - DETENT 15 - MAIN SHAFT CLUTCH ASSEMBLY
ENCODER BOLT
65 - FRONT 41- SHIFT 17 - CLUTCH ASSEMBLY OUTPUT
SLINGER
43 - SHIFT    67 - INPUT
19 - BARREL CAM                      SHAFT SNAP SHAFT SNAP
RING RING 44 - WORM
SHAFT 68 - INPUT 20 - SHIFT SHAFT
CLIP 45 - WORM
SHAFT, 69 - FRONT
21 - OIL TUBE O-RING BEARING, OUTPUT
AND E-CLIP
22 - OIL PUMP 46 - ID TAG 70 -
STUDS 47 - REAR
OUTPUT📷 1
23 - SHIFT SHAFT SPACER -
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BEARING📷 1
48 - FILL 24 - CLUTCH CAM AND DRAIN -
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PLUG📷 51
1. Place the transfer case in a shallow pan and remove the fill and drain plugs to drain the remainder of the fluid.
1 - HOLDER C-3281 2 - REAR COMPANION FLANGE
2. Using Holder C-3281 (1), remove the rear flange (2) nut.
3. Remove the rear output flange from the main shaft. If necessary, use a suitable 2 or 3 jaw puller to remove the output flange.
4. Remove the damper bolts and the damper from the transfer case, (if equipped).
5. Remove the rear cover bolts and the rear cover from the transfer case.
6. Remove encoder screws and the encoder from the transfer case.
7. Remove o-ring from the encoder.
8. Using a suitable pry tool, remove the encoder seal from the transfer case.
9. Remove the shift shaft snap ring from the transfer case.
10. Remove shift motor bolts and the shift motor from the transfer case.
11. Remove the o-ring from the shift motor.
12. Using a suitable pry tool, remove shift motor seal from the transfer case.
13. Remove the worm shaft snap ring from the transfer case.
CAUTION: Carefully unthread (rotate clockwise) the worm shaft to remove it from the transfer case. Failure to follow this caution may result in parts damage.
14. Remove the worm shaft from the transfer case
NOTE: Some prying may be necessary to break the seal between the front and rear case. Use care to not damage the sealing surfaces.
15. Remove the bolts retaining the rear housing to the front housing and separate the housings.
16. Remove the oil pump assembly.
1 - OIL TUBE 2 - O-RING SEAL
17. Remove oil tube (1) from the oil pump and remove the o-ring (2).
18. Remove the pick-up magnet from the magnet pocket.
NOTE: For ease of installation note the orientation of the worm shaft drive gear inner splines to the shift shaft outer splines.
19. Remove the worm drive gear.
NOTE: For ease of installation note the orientation of the clutch cam inner splines to the shift shaft outer splines.
20. Remove the clutch cam.
21. Remove the clutch upper snap ring.
22. Remove the clutch shim.
23. Remove the thrust collar.
24. Remove the upper thrust bearing race.
25. Remove the upper thrust bearing.
26. Remove the upper shift lever.
27. Remove the shift lever balls.
28. Remove the lower shift lever.
29. Remove the lower thrust bearing.
30. Remove the lower thrust bearing race.
31. Remove the clutch apply piston.
NOTE: For ease of installation note the assembly orientation of the 4 identical springs.
32. Remove the clutch return springs.
33. Remove the clutch pack.
34. Remove the inner clutch hub.
35. Remove the clutch drum thrust washer (1) and snap ring (2).
36. Remove the outer clutch drum from the mainshaft drive sprocket.
37. Remove the front drive sprocket snap ring.
38. Remove the front drive sprocket, mainshaft drive sprocket and drive chains as one.
39. Remove the shift shaft spacer.
NOTE: For ease of installation note the orientation of the barrel cam inner splines to the shift shaft outer splines.
40. Remove the barrel cam.
41. Remove the shift shaft.
42. Remove the main shaft from the transfer case.
43. Remove the detent assembly.
NOTE: For ease of assembly note the orientation of the shift fork to the shift rail.
44. Remove the range shift rail assembly and range sleeve. Remove the rail, bracket, spring and washers from the shift fork.
45. Remove the retaining snap ring from the front output shaft.
1 - FRONT HOUSING 2 - FRONT OUTPUT SHAFT
46. Remove the front output shaft (2) from the transfer case (1).
47. Remove the chain guide rail screws and the chain guide rails.
48. Using a suitable pry tool or a screw mounted in a slide hammer, remove the input gear seal. Remove the input gear snap ring.
49. Remove the input planetary gear assembly from the front housing.
50. Remove the snap-ring holding the input gear into the planetary gear.
51. Remove the lock plate from the input and planetary gear assembly.
52. Remove the thrust washer from the input and planetary gear assembly.
53. Remove the input gear from the planetary gear.
54. Remove the tabbed thrust washer from the planetary gear.
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GEAR CASE
2 - INPUT BEARING 26 - SHIFT 50 - FRONT
SNAP RING BEARING
27 - SHIFT    51- OUTPUT
3 - INPUT BEARING HOUDINI RING       SHAFT         SHAFT GEAR
BEARING SNAP RING
28 - FLANGE 52- OUTPUT 4 - CARRIER SNAP RING
NUT SHAFT GEAR
29 - FLANGE 53 - SHIFT 5 - CARRIER LOCK PLATE
O-RING BRACKET
30 - 54 - OIL PUMP 6 - THRUST WASHER COMPANION
FLANGE 31 -
COMPANION 55 - DRIVE 7 - INPUT GEAR (SHAFT)
SLINGER
56 - FRONT 32 - DAMPER
OUTPUT
8 - TABBED THRUST WASHER BOLTS (if
SHAFT SNAP equipped)
RING
33 - DAMPER 57 - CHAIN 9 - PLANETARY GEAR ASSEMBLY (if equipped) GUIDE RAILS
                                     34 - REAR     58 - CHAIN
10 - SHIFT FORK                      COVER         GUIDE RAIL
BOLTS BOLTS
35 - OUTPUT 11 - SHIFT RAIL SPRING AND WASHERS 59 - MAGNET
BEARING
37 -          61 -
13 - RANGE SLEEVE                    ENCODER ALIGNMENT
BOLTS DOWEL
38 - SHIFT 14 - SHIFT RAIL MOTOR 62 - DETENT
BOLTS
39 - SHIFT 63 - DETENT 15 - MAIN SHAFT CLUTCH ASSEMBLY
ENCODER BOLT
41- SHIFT 65 - FRONT 17 - CLUTCH ASSEMBLY
SLINGER📷 1
43 - SHIFT  67 - INPUT
19 - BARREL CAM                                                SHAFT SNAP SHAFT SNAP
RING RING 44 - WORM
SHAFT 68 - INPUT 20 - SHIFT SHAFT
CLIP 45 - WORM
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SHAFT, 69 - FRONT📷 1
21 - OIL TUBE O-RING BEARING, OUTPUT
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AND E-CLIP📷 1
70 - 22 - OIL PUMP 46 - ID TAG ATTACHMENT
STUDS 47 - REAR
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OUTPUT📷 1
23 - SHIFT SHAFT SPACER -
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BEARING📷 1
48 - FILL 24 - CLUTCH CAM AND DRAIN -
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PLUG📷 61
NOTE: Lubricate all seals with MOPAR® 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 - 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 C-4210 3 - HANDLE C-4171
3. Using a suitable pry tool or a screw mounted in a slide hammer, remove the font output shaft seal. 4. Using Installer 6061 inverted, 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 Installer C-4210 (2). 6. Install the front output shaft seal using Installer 6560.
1 - REAR CASE 2 - REMOVER/INSTALLER C-4210 3 - HANDLE C-4171
7. Remove the rear output shaft bearing from the rear case using Installer 6436 (2) inverted and Handle C- 4171 (3). 8. Install the rear output shaft bearing into the rear case using Remover/Installer C-4210 (2) inverted and Handle C-4171 (3).
9. Remove shift shaft bearing snap ring.
1 - HANDLE C-4171 2 - INSTALLER/REMOVER 5066
10. Remove shift shaft bearing using Handle C-4171 (1) and Installer/Remove 5066 (2).
1 - HANDLE C4171 2 - INSTALLER/REMOVER 5066
11. Install shift shaft bearing using Handle C-4171 and Installer/Remover 5066 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 N.m (44-71 in. lbs.).
1 - FRONT HOUSING 2 - FRONT OUTPUT SHAFT
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.
1 - HANDLE C-4171 2 - INSTALLER 9672
23. Using Installer 9672 (2) and Handle C-4171 (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.
26.   Install the range sleeve into the shift fork.
27.   Install the range shift assembly and range sleeve.
28. Install the detent assembly.
29. Install the mainshaft into the transfer case.
30. 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.
31. Install the barrel cam.
32. Install the shift shaft spacer.
33. Install the front drive sprocket, mainshaft drive sprocket and drive chains as one.
34. Install the front drive sprocket snap ring.
35. Install the outer clutch drum onto the mainshaft drive sprocket.
36. Install the clutch drum snap ring (2) and thrust washer (1).
37. Install the inner clutch hub.
38. Starting with a friction disc and ending with a friction disc, install the clutch pack.
NOTE: The four identical springs must be installed in the orientation shown in illustration.
39. Install the clutch return springs.
40. Install the clutch apply piston with the lettering up and the stepped face down.
41. Install the lower bearing race with the race fitting into the grove in the reaction plate.
42. Install the lower bearing.
43. Install the lower shift lever.
44. Install the shift lever balls into their pockets.
45. Install the upper shift lever.
46. Install the upper thrust bearing.
47. Install the upper bearing race.
48. Install the thrust collar.
49. Install the clutch shim.
50. 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.
51. 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.
52. Install the worm drive gear.
53. Install the magnet into the magnet pocket.
1 - OIL TUBE 2 - O-RING SEAL
54. Install a new o-ring (2) onto the oil pump tube (1).
55. Lubricate the oil tube o-ring with MOPAR® ATF+4 and install the tube into the oil pump. 56. Install the oil pump assembly.
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).
57. Apply bead of Mopar® Gasket Maker, or equivalent, to one of the mating surfaces of the front or rear housing. 58. Install the rear housing onto the front housing. Install the housing bolts. Tighten housing bolts in a crisscross pattern to 27 N.m (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.
59. 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.
60. Install the worm shaft snap ring.
61. Using a suitable installer, install the shift motor seal.
62. Install a new o-ring onto the shift motor.
NOTE: Note the orientation of the shift motor shaft to the worm gear shaft.
63. Install the shift motor onto the transfer case. Install the shift motor bolts. Tighten the shift motor bolts to 13 N.m (9 ft. lbs.).
NOTE: It may be necessary to pull out on the shift shaft to properly seat the shift shaft snap ring.
64. Install the shift shaft snap ring.
65. Using a suitable installer, install the shift shaft seal.
66. Install a new o-ring onto 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.
67. Install the encoder onto the rear transfer case housing. Install the encoder screws. Tighten the screws to 5-
8 N.m (44-71 in. lbs.).
1 - HANDLE C-4171 2 - INSTALLER/REMOVER C-4210
68. Using a suitable pry tool or a screw mounted in a slide hammer, remove the rear cover seal. 69. Using Installer C-4210 (2) and Handle C-4171 (1), install the rear cover seal.
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).
70. Apply bead of Mopar® Gasket Maker, or equivalent, to one of mating surfaces of the rear cover or rear housing. Align the tabs on the rear cover to the tabs on the rear housing and install the rear cover. Install the rear cover bolts. Tighten the rear cover bolts in a crisscross pattern to 27 N.m (20 ft. lbs.).
71. Install the damper, (if equipped) and the damper bolts onto the transfer case. Tighten the damper bolts to 27 N.m (20 ft. lbs.).
72. Install the companion flange onto the mainshaft.
1 - HOLDER C-3281 2 - REAR COMPANION FLANGE
73. Using Holder C-3281 (1), install the rear output flange (2) nut. Tighten the nut to 122-176 N.m (90-130 ft. lbs.).
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CLUTCH PACK📷 1
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.
1 - MAINSHAFT 11 -
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RACE📷 1
2 - DRIVE SPROCKET 12 -
BEARING 13 -
LOWER 3 - OUTER CLUTCH DRUM
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LEVER📷 1
14 - 4 - SNAP RING SHIFT
BALLS 15 -
UPPER 5 - THRUST WASHER
LEVER 16 -
UPPER 6 - INNER CLUTCH HUB
BEARING 17 -
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UPPER📷 1
7 - CLUTCH REACTION PLATE (total of 7) THRUST
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RACE📷 1
18 - 8 - CLUTCH FRICTION DISC (total of 8) THRUST
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COLLAR📷 1
19 - 9 - CLUTCH RETURN SPRINGS (total of 4) CLUTCH
SHIM 20 - SNAP 10 - CLUTCH APPLY PISTON
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RING📷 15
1. Remove the clutch upper snap ring.
2. Remove the clutch shim.
3. Remove the thrust collar.
4. Remove the upper thrust bearing race.
5. Remove the upper thrust bearing.
6. Remove the upper shift lever.
7. Remove the shift lever balls.
8. Remove the lower shift lever.
9. Remove the lower thrust bearing.
10. Remove the lower bearing race.
11. Remove the clutch apply piston.
NOTE: For ease of installation note the assembly orientation of the 4 identical springs.
12. Remove the clutch return springs.
NOTE: For ease of installation note the assembly configuration of the clutch plates and friction discs.
13. Remove the clutch pack.
14. Remove the inner clutch hub.
15. Remove the clutch hub thrust washer (1) and snap ring (2).
16. Remove the outer clutch drum from the main shaft and drive sprocket.
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CLUTCH PACK📷 2
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.
1 - MAINSHAFT 11 -
RACE 2 - DRIVE SPROCKET 12 -
BEARING 13 -
LOWER 3 - OUTER CLUTCH DRUM
LEVER 14 -
SHIFT 4 - SNAP RING
BALLS 15 -
UPPER 5 - THRUST WASHER
LEVER 16 -
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UPPER📷 1
6 - INNER CLUTCH HUB THRUST
BEARING 17 -
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UPPER📷 1
7 - CLUTCH REACTION PLATE (total of 7) THRUST
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RACE📷 1
18 - 8 - CLUTCH FRICTION DISC (total of 8) THRUST
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COLLAR📷 1
19 - 9 - CLUTCH RETURN SPRINGS (total of 4) CLUTCH
SHIM 20 - SNAP 10 - CLUTCH APPLY PISTON
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RING📷 15
1. Install the outer clutch drum onto the main shaft and drive sprocket.
2. Install the clutch hub snap ring (2) and thrust washer (1).
3. Install the inner clutch hub.
4. Starting with friction disc and ending with a friction disc, install the clutch pack.
NOTE: The four identical springs must be installed in the orientation shown in illustration.
5. Install the clutch return springs.
6. Install the clutch apply piston with the lettering up and the stepped face down.
7. Install the lower thrust bearing race.
8. Install the lower thrust bearing.
9. Install the lower shift lever.
10. Install the shift lever balls into their pockets.
11. Install the upper shift lever.
12. Install the upper thrust bearing.
13. Install the upper thrust bearing race.
14. Install the thrust collar.
15. Install the clutch shim.
16. Install the clutch upper snap ring.
FLUID
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MODE SENSOR VOLTAGES
TRANSFER CASE POSITION                                                Voltage
             4WD LOW                                                       0.25 - 0.80
NEUTRAL 1.10 - 1.25📷 4
2H                                                         1.45 - 2.00
         4WD AUTO (ACTIVE)                                                 2.00 - 4.75

Removal

1
Remove the wiring harness electrical connector from the encoder.
2
Remove the screws securing the encoder to the rear transfer case housing.
3
Remove the encoder from the transfer case.
4
Remove the o-ring seal from the encoder.

Installation

1
Install a NEW o-ring seal onto 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.
2
Install the encoder onto the rear transfer case housing.
3
Install the encoder screws. Tighten the screws to 5-8 N.m (44-71 in. lbs.).
4
Install the electrical wiring harness connector onto the encoder.
ASSEMBLY-SHIFT MOTOR
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