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Section 13 (Mp3023 Transfer Case (Service Information)): Disassembly

WARNING: This page is about a different variant/trim than selected.
GC0209188Courtesy of CHRYSLER GROUP, LLC
1 - HOUDINI RETAINING RING 36 - COUPLING
2 - INPUT BALL BEARING 37 - RETAINING RING
3 - RETAINING RING 38 - BEARING
4 - CARRIER LOCK PLATE 39 - REAR CASE HALF ASSEMBLY
5 - FRONT CARRIER THRUST WASHER 40 - BOLT
6 - INPUT GEAR ASSEMBLY 41 - SCREW
7 - CARRIER THRUST SHIM 42 - RADIAL SEAL RING
8 - PLANETARY CARRIER ASSEMBLY 43 - SENSOR
9 - RANGE SLEEVE 44 - SCREW
10 - MAINSHAFT ASSEMBLY 45 - RETAINING RING
11 - OIL PUMP ASSEMBLY 46 - SCREW
12 - REAR THRUST WASHER 47 - IDENTIFICATION TAG
13 - REAR WEAR SLEEVE 48 - FILL/DRAIN PLUG
14 - REAR OUTPUT FLANGE 49 - REAR BEARING
15 - O-RING SEAL 50 - SHIFT SHAFT BEARING RETAINING RING
16 - FLANGE NUT 51 - SHIFT SHAFT BEARING
17 - SCREW 52 - TUBE & SCREEN ASSEMBLY
18 - SHIFT MOTOR 53 - O-RING SEAL
19 - WORM SHAFT OIL SEAL 54 - MAGNET
20 - RETAINING RING 55 - SCREW
21 - RETAINING RING 56 - SPRING
22 - BALL BEARING 57 - DETENT POPPET
23 - WORM SHAFT 58 - CHAIN
24 - SHIFT RAIL 59 - SPROCKET
25 - RANGE FORK PAD 60 - RETAINING RING
26 -RANGE FORK 61 - FRONT BEARING
27 - SLEEVE WASHER 62 - FRONT CASE HALF ASSEMBLY
28 - SPRING 63 - DOWEL BUSHING
29 - BRACKET ASSEMBLY 64 - RADIAL SEAL RING
30 - RETAINING RING 65 - FRONT WEAR SLEEVE
31 - BARREL CAM 66 - FRONT OUTPUT FLANGE
32 - SHIFT SHAFT ASSEMBLY 67 -RETAINING RING
33 - BUSHING 68 - INPUT SEAL
34 - CLUTCH CAM 69 - VENT
35 - GEAR  
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. Place the transfer case in a shallow pan and remove the fill and drain plugs to drain the remainder of the fluid.
    GC0209214Courtesy of CHRYSLER GROUP, LLC
  2. Using Holder (special tool #C-3281, Holder, Flange) (1), remove the rear flange (2) nut.
    GC0209213Courtesy of CHRYSLER GROUP, LLC
  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.
    GC0209212Courtesy of CHRYSLER GROUP, LLC
  4. Remove encoder screws and the encoder from the transfer case.
    GC0209211Courtesy of CHRYSLER GROUP, LLC
  5. Remove the shift shaft snap ring from the transfer case.
    GC0209210Courtesy of CHRYSLER GROUP, LLC
  6. Remove shift motor bolts and the shift motor from the transfer case.
    GC0209225Courtesy of CHRYSLER GROUP, LLC
  7. Remove the O-ring from the shift motor.
    GC0209209Courtesy of CHRYSLER GROUP, LLC
  8. Using a suitable pry tool, remove shift motor seal from the transfer case.
    GC0209208Courtesy of CHRYSLER GROUP, LLC
  9. 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.

    GC0209207Courtesy of CHRYSLER GROUP, LLC
  10. Remove the worm shaft from the transfer case.
    GC0209206Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Some prying may be necessary to break the seal between the front and rear case. Use care to not damage the sealing surfaces.

  11. Remove the bolts retaining the rear housing to the front housing and separate the housings.
    GC0209204Courtesy of CHRYSLER GROUP, LLC
  12. Remove the output shaft thrust washer.
    GC0209205Courtesy of CHRYSLER GROUP, LLC
  13. Remove the oil pump assembly.
    GC0209252Courtesy of CHRYSLER GROUP, LLC
  14. Remove oil tube (1) from the oil pump and remove the O-ring (2).
    GC0209203Courtesy of CHRYSLER GROUP, LLC
  15. 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.

    GC0209251Courtesy of CHRYSLER GROUP, LLC
  16. 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.

    GC0209250Courtesy of CHRYSLER GROUP, LLC
  17. Remove the clutch cam.
    GC0209249Courtesy of CHRYSLER GROUP, LLC
  18. Remove the clutch upper snap ring.
    GC0209248Courtesy of CHRYSLER GROUP, LLC
  19. Remove the clutch shim.
    GC0209247Courtesy of CHRYSLER GROUP, LLC
  20. Remove the thrust collar.
    GC0209246Courtesy of CHRYSLER GROUP, LLC
  21. Remove the upper thrust bearing race.
    GC0209245Courtesy of CHRYSLER GROUP, LLC
  22. Remove the upper thrust bearing.
    GC0209244Courtesy of CHRYSLER GROUP, LLC
  23. Remove the upper shift lever.
    GC0209243Courtesy of CHRYSLER GROUP, LLC
  24. Remove the shift lever balls.
    GC0209242Courtesy of CHRYSLER GROUP, LLC
  25. Remove the lower shift lever.
    GC0209241Courtesy of CHRYSLER GROUP, LLC
  26. Remove the lower thrust bearing.
    GC0209240Courtesy of CHRYSLER GROUP, LLC
  27. Remove the lower thrust bearing race.
    GC0209239Courtesy of CHRYSLER GROUP, LLC
  28. Remove the clutch apply piston.
    NOTE:

    For ease of installation note the assembly orientation of the 4 identical springs.

    GC0209202Courtesy of CHRYSLER GROUP, LLC
  29. Remove the clutch return springs.
    GC0209238Courtesy of CHRYSLER GROUP, LLC
  30. Remove the clutch pack.
    GC0209237Courtesy of CHRYSLER GROUP, LLC
  31. Remove the inner clutch hub.
    GC0209236Courtesy of CHRYSLER GROUP, LLC
  32. Remove the clutch drum thrust washer (1) and snap ring (2).
    GC0209235Courtesy of CHRYSLER GROUP, LLC
  33. Remove the outer clutch drum from the main shaft drive sprocket.
    GC0209201Courtesy of CHRYSLER GROUP, LLC
  34. Remove the front drive sprocket, main shaft drive sprocket and drive chain as one.
    GC0209234Courtesy of CHRYSLER GROUP, LLC
  35. 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.

    GC0209233Courtesy of CHRYSLER GROUP, LLC
  36. Remove the barrel cam.
    GC0209232Courtesy of CHRYSLER GROUP, LLC
  37. Remove the shift shaft.
    GC0209200Courtesy of CHRYSLER GROUP, LLC
  38. Remove the main shaft from the transfer case.
    GC0209199Courtesy of CHRYSLER GROUP, LLC
  39. Remove the detent assembly.
    GC0209198Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    For ease of assembly note the orientation of the shift fork to the shift rail.

  40. Remove the range shift rail assembly and range sleeve. Remove the rail, bracket, spring and washers from the shift fork.
    GC0209197Courtesy of CHRYSLER GROUP, LLC
  41. Remove the retaining snap ring from the front output shaft.
    GC0209196Courtesy of CHRYSLER GROUP, LLC
  42. Remove the front output shaft from the transfer case.
    GC0209195Courtesy of CHRYSLER GROUP, LLC
  43. Using a suitable pry tool or a screw mounted in a slide hammer, remove the input gear seal. Remove the input gear snap ring.
    GC0209224Courtesy of CHRYSLER GROUP, LLC
  44. Remove the input planetary gear assembly from the front housing.
    GC0209223Courtesy of CHRYSLER GROUP, LLC
  45. Remove the snap-ring holding the input gear into the planetary gear.
    GC0209222Courtesy of CHRYSLER GROUP, LLC
  46. Remove the lock plate from the input and planetary gear assembly.
    GC0209221Courtesy of CHRYSLER GROUP, LLC
  47. Remove the thrust washer from the input and planetary gear assembly.
    GC0209220Courtesy of CHRYSLER GROUP, LLC
  48. Remove the input gear from the planetary gear.
    GC0209219Courtesy of CHRYSLER GROUP, LLC
  49. Remove the tabbed thrust washer from the planetary gear.
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