Oil Pump And Rear Case

WARNING: This page is about a different variant/trim than selected.

CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft inner bearing race and will become misaligned if the bolts are loosened. If the transfer case failure has generated any debris which may have become trapped in the oil pump. The rear case and oil pump assembly MUST be replaced.

Lubricate the oil pump components before installation. Prime the oil pickup tube by pouring a little oil into the tube before installation.

Install new o-ring in pickup tube inlet of oil pump.
Position oil pickup tube and filter in rear case. Be sure pickup filter is seated in case pocket and that pickup tube is aligned in case notches. Be sure hose that connects tube to filter is securely positioned.
Install the transfer case position sensor. Tighten the sensor to 20-34 N.m (16-25 ft.lbs.).

Fig 1: Installing Transfer Case Position Sensor
Courtesy of DAIMLERCHRYSLER CORP.
Install the shift sector support. Tighten the sector support to 27-42 N.m (20-30 ft.lbs.).

Fig 2: Installing Shift Sector Support
Courtesy of DAIMLERCHRYSLER CORP.
Install detent plunger and spring into the front case half.

Fig 3: Installing Detent Plug, Spring & Plunger
Courtesy of DAIMLERCHRYSLER CORP.
Install new o-ring on detent plug and install plug in front case. See Fig 3 . Tighten plug to 16-25 N.m (12-18 ft. lbs.).
Install shift lever onto the sector shaft.

Fig 4: Installing Shift Lever
Courtesy of DAIMLERCHRYSLER CORP.
Install the shift lever bolt. Tighten the bolt to 20-34 N.m (15-25 ft.lbs.)

Fig 5: Installing Shift Lever Bolt
Courtesy of DAIMLERCHRYSLER CORP.
Shift the transfer case into a 4WD range. This will raise the mainshaft slightly and make installation of the rear case half much easier.
Verify that the transfer case alignment dowels are properly installed.
Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into case interior.
Align oil pump with mainshaft and align shift rail with bore in rear case. Then install rear case and oil pump assembly. Be sure oil pickup tube remains in position during case installation.

Fig 6: Installing Rear Case Half
Courtesy of DAIMLERCHRYSLER CORP.

CAUTION: Verify that shift rail, and case alignment dowels (Fig. 81) are seated before installing any bolts. Case could be cracked if shaft rail or dowels are misaligned.

Fig 7: Locating Case Alignment Dowel

Courtesy of DAIMLERCHRYSLER CORP.

Install 4-5 rear case-to front case bolts to hold rear case in position. Tighten bolts snug but not to specified torque at this time.
Apply Loctite(tm) 242 to remainder of rear case-to-front case bolt threads and install bolts. Tighten all bolts to 20-27 N.m (15-20 ft. lbs.).

Fig 8: Installing Case Half Bolt
Courtesy of DAIMLERCHRYSLER CORP.