Transfer Case MPT3015: Assembly

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

ASSEMBLY

If necessary, use the (special tool #9598, Installer, Seal) and an Arbor Press to install the front output shaft bearings into the front case half.
NOTE:
When pressing bearings into case, be sure to properly support the underside of the case half.
If necessary, use the (special tool #9598, Installer, Seal) and an Arbor Press to install the rear output shaft bearing into the rear case half.
NOTE:
When pressing bearings into case, be sure to properly support the underside of the case half.
If necessary, using (special tool #9672, Installer, Seal) with the (special tool #C-4171, Driver Handle, Universal), install front output shaft seal.
Using the (special tool #9672, Installer, Seal) with the (special tool #C-4171, Driver Handle, Universal), install rear output seal.

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1 - Front Output Shaft

2 - Snap Ring

Install the front output shaft and snap ring.

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1 - Front Output Gear

2 - Mainshaft Assembly

3 - Chain

Simultaneously install the mainshaft assembly, chain and front output gear into the front case half. Allow the bearing on the mainshaft to sit on the snap ring in the front case half.

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1 - Snap Ring

2 - Front Case Half
Using a long pair of snap ring pliers, spread the snap ring in the front case half to allow the bearing and mainshaft assembly to fall into the front case half. Verify that the bearing is secured by the snap ring.

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1 - Oil Tank Deflector
Install the deflector tank into the front case half. The deflector tank will typically not go in with the tank cover on.

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1 - Oil Tank Deflector Cavities
Verify the deflector tank is securely pressed into the cavities in the front case half.

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1 - Oil Tank Deflector

2 - Oil Tank Deflector Cover Tabs
Carefully install the top cover on the deflector tank. Verify all seven locking tabs are secured.

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1 - Oil Deflector Tube

2 - Oil Deflector Tube O-ring
Verify the O-ring is properly installed and not damaged on the deflector tube. Install the oil deflector tube into the deflector tank until the locking tabs are engaged.
Install the rear oil deflector on the mainshaft assembly.

Apply a 1/4" bead of Mopar® RTV to the rear case half mating surface.

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1 - Locating Dowels

2 - Rear Case Half

3 - Front Case Half

Carefully install the rear case half to the front case half and verify the locating dowels are aligned.
NOTE:
Do not force the rear case half.

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1 - Worm Shaft
If the rear case half will not mate with the front the worm shaft in the rear case half may not be aligned with the gear on the clutch assembly. Use a flat blade screwdriver to jiggle the worm shaft slightly until the case halves are mated. Tap lightly with a rubber mallet if necessary to seat the case halves.
Torque the case bolts to 22 N. m (16 Ft. Lbs.) .

If necessary, using the (special tool #2076600210, Installer, Input Shaft Seal), install input shaft seal.

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1 - Shift Motor Mounting Bolts

2 - Transfer Case Shift Motor

3 - Rear Output Flange

4 - Case Bolts

Clean the Loctite™ from the threads with a thread chaser before installing new motor bolts. Installing new bolts with Loctite™ can cause the case to crack and damage the case half if the old Loctite™ sealer is not removed.
Install the shift motor.
NOTE:
Verify the shift motor position and the sector shaft orientation are aligned.
Install new shift motor mounting bolts and torque to 25 N. m (18 Ft. Lbs.) .
Install the rear output flange on the rear output shaft.
Install the rear output flange spline seal.
Install the output flange nut and torque to 165 N. m (122 Ft. Lbs.) .
Install the transfer case. Refer to REMOVAL AND INSTALLATION .