‹

Transfer Case Actuator

Transmission and Drivetrain › Transfer Case
Unified entry — merged from multiple cross-listed pages in the original manual.

Labor

Replace — Actuator Motor0.7 hr
Warranty 0.0 hrSkill B
Replace — Actuator Motor0.7 hr
Warranty 0.0 hrSkill B
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
Fig. 1
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Fig. 8
  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.
Fig. 1
Fig. 1
  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.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
  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
Fig. 1
Fig. 1
Fig. 2
Fig. 2
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
Fig. 1
Fig. 1
Fig. 2
Fig. 2
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
Fig. 1
Fig. 1
Fig. 2
Fig. 2
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.
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.
Fig. 1
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Fig. 6
  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
Fig. 1
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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.
Fig. 1
Fig. 1
  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.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
  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
Fig. 1
Fig. 1
Fig. 2
Fig. 2
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
Fig. 1
Fig. 1
Fig. 2
Fig. 2
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
Fig. 1
Fig. 1
Fig. 2
Fig. 2
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.
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.
Fig. 1
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Fig. 2
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Fig. 3
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Fig. 6
  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
Fig. 1
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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.
Fig. 1
Fig. 1
  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.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
  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
Fig. 1
Fig. 1
Fig. 2
Fig. 2
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
Fig. 1
Fig. 1
Fig. 2
Fig. 2
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
Fig. 1
Fig. 1
Fig. 2
Fig. 2
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.
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.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
Fig. 5
Fig. 5
Fig. 6
Fig. 6
  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
Fig. 1
Fig. 1
Fig. 2
Fig. 2
Fig. 3
Fig. 3
Fig. 4
Fig. 4
Fig. 5
Fig. 5
Fig. 6
Fig. 6
Fig. 7
Fig. 7
Fig. 8
Fig. 8
  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.
Fig. 1
Fig. 1
  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.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
  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
Fig. 1
Fig. 1
Fig. 2
Fig. 2
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
Fig. 1
Fig. 1
Fig. 2
Fig. 2
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
Fig. 1
Fig. 1
Fig. 2
Fig. 2
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.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
MOTOR

Assembly

54 -
MOTOR📷 1

Assembly

54 -
figure
MOTOR

Assembly

54 -
MODE SENSOR📷 1
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
The transfer case mode sensor, also known as "Encoder" (3) which is integrated into the shift motor assembly, provides the Drivetrain Control Module (DTCM) feedback about the position of the transfer case. The sensor consists of a linear analog position sensor that converts the motor output shaft position into a DC signal. The sensor may rotate a full 360 degrees. The DTCM must supply 5V DC (±2.5%) to the sensor whenever the DTCM is not in sleep mode and monitors the shift motor position. The sensor position is monitored when the ignition is in the RUN position and for TBD seconds after the ignition is shifted to the ACC position. The sensor is mechanically linked to the shaft of the cam which allows the transfer case to shift. The mode sensor will draw less than 30 mA of current during operation.
figure
MODE SENSOR📷 1
NOTE: All the parameter voltages referred to in the following information are calibrated items in the controller software and are subject to change.
During normal vehicle operation, the DTCM monitors the mode sensor outputs at least every 2 milliseconds when the shift motor is stationary or active. The mode sensor position will be considered invalid by the DTCM if the voltage is greater than 3.51 V or if it is less than 1.52 V. The DTCM shall consider t-case position based on the MODE SENSOR VOLTAGES table listed below.
figure
SHIFT MOTOR/MODE SENSOR ASSEMBLY📷 1
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
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.
figure
SHIFT MOTOR/MODE SENSOR ASSEMBLY📷 1
Shifting in the transfer case occurs when a Pulse Width Modulated (PWM) voltage is supplied to the shift motor by the Drivetrain Control Module (DTCM). A linear analog position sensor located inside the shift motor, provides the DTCM with the motors' angular, rotational position. With this information, the DTCM 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.
figure
SHIFT MOTOR/MODE SENSOR ASSEMBLY📷 3
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.
1 - BOLTS 2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
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.
1 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY 2 - SHIFT SECTOR 3 - TRANSFER CASE
4. Separate the shift motor and mode sensor assembly (1) from the transfer case (3) and shift sector (2).
1 - SEAL RING 2 - SHIFT MOTOR
5. Remove the seal ring (1) from the shift motor (2).
figure
figure
figure
SHIFT MOTOR/MODE SENSOR ASSEMBLY📷 5
1 - SEAL RING 2 - SHIFT MOTOR
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.
NOTE: Verify that the missing tooth (2) in the shift motor drive spline (1).
NOTE: 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
3. Position the shift motor and mode sensor assembly (1) onto the transfer case (3) and shift sector (2).
1 - BOLTS 2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
4. Install the bolts (1) to hold the assembly (2) onto the transfer case. Tighten the bolts to 25-28 N.m (18.5- 20.5 ft. lbs.).
CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar® Lock & Seal or Loctite™ 242 to replenish the lock patch material originally found on the bolts
5. Engage the wiring connector to the shift motor and mode sensor assembly. 6. Lower vehicle and verify transfer case operation.
figure
figure
figure
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figure
MOTOR SPRING
40- SHIFT 64 - DETENT 16 - DRIVE SPROCKET
ELECTRIC SHIFT MECHANISM
The electronically controlled wet clutch pack uses and 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 discs are alternately splined to the front and rear drive shafts. When normal force is applied to this clutch pack, torque is transferred to equalize speed differences between front and rear axles.
Transfer of torque from one wheel to the other on an axle is accomplished by using Brake Traction Control. Under the right conditions the vehicle can be driven by just one wheel.
MOTOR SPRING
40- SHIFT 64 - DETENT 16 - DRIVE SPROCKET
MOTOR SPRING
40- SHIFT 64 - DETENT 16 - DRIVE SPROCKET
MODE SENSOR📷 2
1 - SHIFT MOTOR 2 - ID TAG 3 - ENCODER
The transfer case Encoder (3) provides the Final Drive Control Module (FDCM) feedback about the position of the transfer case. The sensor consists of a linear analog position sensor that converts the motor output shaft position into a DC signal. The sensor may rotate a full 360 degrees. The FDCM must supply 5VDC (+/- 0.5v) to the sensor whenever the FDCM is not in sleep mode and monitors the shift motor position. The sensor position is monitored when the ignition is in the RUN position and for 10 seconds after the ignition is shifted to the OFF position. The sensor is mechanically linked to the shaft of the cam which allows the transfer case to shift. The mode sensor will draw less than 20 mA of current during operation.
figure
figure
MODE SENSOR
During normal vehicle operation, the DTCM monitors the mode sensor outputs at least every 2 milliseconds when the shift motor is stationary or active. The mode sensor position will be considered invalid by the DTCM if the voltage is greater than 4.75 V or if it is less than 0.25 V.
NOTE: All the parameter voltages referred to in the following information are calibrated items in the controller software and are subject to change.
The DTCM shall consider Transfer Case position based on the MODE SENSOR VOLTAGES table listed below:
SHIFT MOTOR/MODE SENSOR ASSEMBLY📷 1
1 - SHIFT MOTOR 2 - ID TAG 3 - ENCODER
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.
figure
OPERATION-SHIFT MOTOR📷 1
1 - SHIFT MOTOR 2 - ID TAG 3 - ENCODER
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.
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REMOVAL-SHIFT MOTOR📷 3
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.
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.
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INSTALLATION-SHIFT MOTOR📷 2
1. Install a NEW shift motor o-ring seal onto the shift motor.
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.
2. Install the shift motor onto the transfer case. 3. Install the shift motor bolts. Tighten the shift motor bolts to 13 N.m (9 ft. lbs.). 4. Install the electrical wiring harness connector onto the shift motor.
SWITCH-TRANSFER CASE SELECTOR
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