Clutch Pack
WARNING: This page is about a different variant/trim than selected.
| 1 - BOTTOM (OUTER LUGS) CLUTCH PLATE |
| 2 - CLUTCH RETAINER |
NOTE:
Soak new clutch friction plates in transfer case fluid for 20 minutes prior to installation.
- Install the bottom (outer lugs) clutch plate (1) into the clutch retainer (2). Continue installing clutch plates, a disc with inner teeth followed by a disc with outer lugs, into the clutch retainer (2). See Fig 1.
1 - TOP (INNER TEETH) CLUTCH PLATE 2 - CLUTCH RETAINER - install the top (inner teeth) clutch plate (1) into the clutch retainer (2). See Fig 2.
1 - OUTPUT SHAFT 2 - WAVY SPRING - Install the wave spring (2) onto the main shaft (1). See Fig 3.
1 - OUTPUT SHAFT 2 - CLUTCH PRESSURE PLATE CAUTION: When installing the clutch pressure plate, make sure that the wave spring remains piloted on the underside of the plate. Check that the spring does not protrude between the plate and the mainshaft. - Install the clutch pressure plate (2) onto the main shaft (1) and clutch assembly. See Fig 4.
1 - OUTPUT SHAFT 2 - THRUST BEARING - Install the thrust bearing (2) onto the main shaft (1). See Fig 5.
1 - OUTPUT SHAFT 2 - SUPPORT PLATE - Install the thrust bearing support plate (2) onto the main shaft (1). See Fig 6.
1 - OUTPUT SHAFT 2 - RETAINING RING NOTE: The clutch pressure plate must be engaged with the inner drum and held down when installing the retaining ring. - Install the thrust bearing support plate retaining ring (2) onto the main shaft (1). See Fig 7.
1 - SUPPORT PLATE 2 - TAB 3 - BOLT HOLES - Rotate the thrust bearing support plate (1) so that the tab (2) is pointed between the two bolt holes (3) as shown. See Fig 8.
1 - CLUTCH LEVER ASSEMBLY - Install the clutch lever assembly (1) onto the mainshaft and shift rail. See Fig 9.
1 - REAR HOUSING 2 - FRONT HOUSING - 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.
- Verify that the tab on the thrust bearing support plate is aligned with the housing alignment dowel furthest from the front output shaft.
- Install the rear housing (1) into the front housing (2). See Fig 10.
1 - REAR HOUSING 2 - BOLTS 3 - FRONT HOUSING - 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 criss-cross pattern. Tighten the bolts to 27 N.m (20 ft.lbs.). See Fig 11.
1 - OUTPUT SHAFT 2 - RETAINING RING 3 - REAR HOUSING NOTE: Pull up on the main shaft when installing the retaining ring to ensure that the ring is fully engaged into the groove. - Install the rear main shaft (1) retaining ring (2). See Fig 12.
1 - OUTPUT SHAFT 2 - OIL PUMP OUTER ROTOR 3 - REAR HOUSING Lubricate the oil pump components with transmission fluid before installation.
- Install the oil pump outer rotor (2) onto the main shaft (1) and into the rear housing (3). See Fig 13.
1 - OUTPUT SHAFT 2 - OIL PUMP INNER ROTOR 3 - REAR HOUSING - Install the oil pump inner rotor (2) onto the main shaft (1) and into the rear housing (3). See Fig 14.
1 - REAR HOUSING 2 - CLUTCH LEVER RAIL - Install the clutch lever rail (2) into the rear housing (1) and clutch lever. See Fig 15.
1 - CLUTCH LEVER RAIL PLUG - Install the clutch lever rail plug (1) into the rear housing. See Fig 16.
1 - ANTI-ROTATION BRACKET 2 - SHIFT RAIL - Install the anti-rotation bracket (1) onto the shift rail (2). See Fig 17.
1 - SECTOR ROLLER 2 - SHIFT RAIL - Install the sector roller (1) onto the shift rail (2). See Fig 18.
- 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 - REAR HOUSING 2 - SEALANT - Apply bead of Mopar® Gasket Maker, or equivalent, to mating surface of rear housing as shown (2). See Fig 19. Keep sealer bead width to maximum of 3 mm (1/8 inch). Do not use excessive amount of sealer as excess could be displaced into the oil pump.
1 - REAR COVER 2 - REAR HOUSING - Install the rear cover (1) onto the rear housing (2). See Fig 20.
1 - REAR HOUSING 2 - REAR COVER 3 - BOLTS - 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 criss-cross pattern. Tighten the bolts to 27 N.m (20 ft.lbs.). See Fig 21.
1 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY 2 - SHIFT SECTOR 3 - TRANSFER CASE - Install the shift motor and mode sensor assembly (1) onto the shift sector (2) and the transfer case (3). See Fig 22.
1 - BOLTS 2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY - 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.). See Fig 23.
1 - REAR COMPANION FLANGE 2 - OUTPUT SHAFT - If necessary, install the transfer case damper onto the transfer case.
- Install the rear output flange (1) onto the main shaft (2). See Fig 24.
1 - HOLDER C-3281 2 - REAR COMPANION FLANGE - Using Holder C-3281 (1), install the rear output flange (2) nut. Tighten the bolts to 122-176 N.m (90-130 ft.lbs.). See Fig 25.