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Section 21 (Mp3023 Transfer Case (Service Information)): Disassembly

WARNING: This page is about a different variant/trim than selected.
Fig 1: Exploded View Of Transfer Case Components
GC0146336Courtesy 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.
    GC0146287Courtesy of CHRYSLER GROUP, LLC
  2. Using Holder (special tool #C-3281, Holder, Flange) (1), remove the rear flange (2) nut.
    GC0146288Courtesy 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.
    GC0146289Courtesy of CHRYSLER GROUP, LLC
  4. Remove encoder screws and the encoder from the transfer case.
    GC0146290Courtesy of CHRYSLER GROUP, LLC
  5. Remove the shift shaft snap ring from the transfer case.
    GC0146291Courtesy of CHRYSLER GROUP, LLC
  6. Remove shift motor bolts and the shift motor from the transfer case.
    GC0083827Courtesy of CHRYSLER GROUP, LLC
  7. Remove the o-ring from the shift motor.
    GC0146292Courtesy of CHRYSLER GROUP, LLC
  8. Using a suitable pry tool, remove shift motor seal from the transfer case.
    GC0146293Courtesy 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.

    GC0146294Courtesy of CHRYSLER GROUP, LLC
  10. Remove the worm shaft from the transfer case
    GC0146295Courtesy 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.
    GC0146298Courtesy of CHRYSLER GROUP, LLC
  12. Remove the output shaft thrust washer.
    GC0146297Courtesy of CHRYSLER GROUP, LLC
  13. Remove the oil pump assembly.
    GC0083047Courtesy of CHRYSLER GROUP, LLC
  14. Remove oil tube (1) from the oil pump and remove the o-ring (2).
    GC0146299Courtesy 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.

    GC0083049Courtesy 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.

    GC0083050Courtesy of CHRYSLER GROUP, LLC
  17. Remove the clutch cam.
    GC0083051Courtesy of CHRYSLER GROUP, LLC
  18. Remove the clutch upper snap ring.
    GC0083052Courtesy of CHRYSLER GROUP, LLC
  19. Remove the clutch shim.
    GC0083053Courtesy of CHRYSLER GROUP, LLC
  20. Remove the thrust collar.
    GC0083054Courtesy of CHRYSLER GROUP, LLC
  21. Remove the upper thrust bearing race.
    GC0083055Courtesy of CHRYSLER GROUP, LLC
  22. Remove the upper thrust bearing.
    GC0083056Courtesy of CHRYSLER GROUP, LLC
  23. Remove the upper shift lever.
    GC0083057Courtesy of CHRYSLER GROUP, LLC
  24. Remove the shift lever balls.
    GC0083058Courtesy of CHRYSLER GROUP, LLC
  25. Remove the lower shift lever.
    GC0083059Courtesy of CHRYSLER GROUP, LLC
  26. Remove the lower thrust bearing.
    GC0083060Courtesy of CHRYSLER GROUP, LLC
  27. Remove the lower thrust bearing race.
    GC0083061Courtesy of CHRYSLER GROUP, LLC
  28. Remove the clutch apply piston.
    NOTE:

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

    GC0146300Courtesy of CHRYSLER GROUP, LLC
  29. Remove the clutch return springs.
    GC0083063Courtesy of CHRYSLER GROUP, LLC
  30. Remove the clutch pack.
    GC0083064Courtesy of CHRYSLER GROUP, LLC
  31. Remove the inner clutch hub.
    GC0083065Courtesy of CHRYSLER GROUP, LLC
  32. Remove the clutch drum thrust washer (1) and snap ring (2).
    GC0083066Courtesy of CHRYSLER GROUP, LLC
  33. Remove the outer clutch drum from the mainshaft drive sprocket.
    GC0146301Courtesy of CHRYSLER GROUP, LLC
  34. Remove the front drive sprocket, mainshaft drive sprocket and drive chain as one.
    GC0083069Courtesy 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.

    GC0083070Courtesy of CHRYSLER GROUP, LLC
  36. Remove the barrel cam.
    GC0083071Courtesy of CHRYSLER GROUP, LLC
  37. Remove the shift shaft.
    GC0146302Courtesy of CHRYSLER GROUP, LLC
  38. Remove the main shaft from the transfer case.
    GC0146303Courtesy of CHRYSLER GROUP, LLC
  39. Remove the detent assembly.
    GC0146304Courtesy 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.
    GC0146305Courtesy of CHRYSLER GROUP, LLC
  41. Remove the retaining snap ring from the front output shaft.
    GC0146306Courtesy of CHRYSLER GROUP, LLC
  42. Remove the front output shaft from the transfer case.
    GC0146307Courtesy 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.
    GC0083828Courtesy of CHRYSLER GROUP, LLC
  44. Remove the input planetary gear assembly from the front housing.
    GC0083829Courtesy of CHRYSLER GROUP, LLC
  45. Remove the snap-ring holding the input gear into the planetary gear.
    GC0083830Courtesy of CHRYSLER GROUP, LLC
  46. Remove the lock plate from the input and planetary gear assembly.
    GC0083831Courtesy of CHRYSLER GROUP, LLC
  47. Remove the thrust washer from the input and planetary gear assembly.
    GC0083832Courtesy of CHRYSLER GROUP, LLC
  48. Remove the input gear from the planetary gear.
    GC0083833Courtesy of CHRYSLER GROUP, LLC
  49. Remove the tabbed thrust washer from the planetary gear.
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