Transfer Case MPT3028: Assembly: Notes

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

ASSEMBLY OF THE MAINSHAFT ASSEMBLY

Install the clutch drum/drive sprocket on the mainshaft and clutch assembly.

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1 - Locating Pin
Install the locating pin from the mainshaft.

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1 - Spacer
Install the spacer.

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1 - Snap Ring

2 - Clutch Drum/Drive Sprocket
Install the snap ring on the mainshaft.

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1 - High/Low Range Gear
Install the high/low range gear onto the mainshaft.

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1 - Snap Ring

2 - Clutch Drum/Drive Sprocket

ASSEMBLY OF THE SHIFT SHAFT ASSEMBLY

Install the shift cam. Align the wide spline on the cam to the shaft when installing.

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1 - Spacer
Install the spacer.

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1 - High/Low Shift Fork
Install the high/low shift fork on the shift shaft.

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1 - Mainshaft/Clutch Assembly

2 - Shift Shaft Assembly
Assemble the shift shaft assembly and the mainshaft assembly on the bench.

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1 - Shift Cam

ASSEMBLY OF THE PLANETARY ASSEMBLY

Install the lower thrust washer.

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1 - Input Gear
Install the input gear.

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1 - Upper Thrust Washer
Install the upper thrust washer.

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1 - Lock Plate
Install the carrier lock plate.

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1 - Snap Ring
Install the snap ring.

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1 - Lower Thrust Washer

ASSEMBLY OF SHAFTS AND HOUSING

If the annulus gear was removed, install the annulus gear into the case half and install snap ring.
Install the planetary gear into the case half.
If necessary, using the (special tool #9598, Installer, Seal) and an Arbor Press, 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, using the (special tool #9598, Installer, Seal) and an Arbor Press, 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.
If necessary, using (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
Install the front output shaft.

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1 - Front Output Shaft

2 - Snap Ring
Install the snap ring.

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1 - Center Hub of Gear (Tall Side)
Install the front output gear on the front output shaft.
NOTE:
The gear must be installed with the taller side of the center of the gear facing up.

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1 - High/Low Range Gear
Install the high/low range gear on the lower portion of the mainshaft assembly.

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1 - Mainshaft/Clutch Assembly

2 - Shift Shaft Assembly
Assemble the shift shaft assembly and the mainshaft assembly together on the bench.

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1 - Colored Chain Link

Assemble the chain on the mainshaft drive sprocket with the colored link facing up as shown in illustration.

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1 - Shift Shaft Assembly

2 - Mainshaft/Clutch Assembly

3 - Chain

Simultaneously install the mainshaft assembly, shift shaft assembly and chain into the front case half.
Verify the chain and shafts are in completely and aligned correctly.

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Install the spacer on the shift shaft if not already installed with the shift shaft assembly.

Use the graphic to verify that the actuator levers are aligned properly to the spacer and cam on the shift shaft assembly. Put the transfer case in 2WD as seen in the graphic.

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1 - Shift Shaft Rear Bearing

2 - Worm Gear

3 - Oil Pump Tube

4 - Oil Pump

Install the oil pump onto the mainshaft.
Install the oil pump tube and magnet.
NOTE:
The magnet should sit under the oil pump tube pickup in the housing.
Install the worm gear on the shift shaft.
NOTE:
The worm gear should be installed with the concave side facing up.
Install the shift shaft rear bearing.

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1 - Spacer

2 - Tabs (should be flat with the side facing up on the spacer)
Install the spacer on the mainshaft.
NOTE:
Take note the orientation of the internal tabs of the spacer for reassembly purposes. The tabs are flat with the side facing up.

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 pins are aligned.
NOTE:
Do not force the case halves.

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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.
Install the case bolts.

If necessary, using the (special tool #2076700210, Installer, Input Shaft Seal), install input shaft seal.

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1 - Shift Motor Mounting Bolts

2 - Transfer Case Shift Motor

3 - Transfer Case Position Sensor Bolts

4 - Transfer Case Position Sensor

Chase and clean the thread lock from the threads before installing the new shift motor bolts. Installing new bolts with thread lock can cause the case to crack and damage the case half if the old thread lock 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.
Install the transfer case position sensor.
Install the transfer case position sensor bolts.
Install the output flange on the rear output shaft.
Install the output flange spline seal.
Install the output flange nut.
Install the transfer case. Refer to REMOVAL AND INSTALLATION .

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1 - Annulus Gear

2 - Planetary Gear Assembly

3 - Snap Ring