Transfer Case MPT3028: Assembly: Notes

ASSEMBLY OF THE MAINSHAFT ASSEMBLY 

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

   Courtesy of CHRYSLER GROUP, LLC

   1 - Snap Ring

   2 - Clutch Drum/Drive Sprocket

2. Install the locating pin from the mainshaft.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Locating Pin

3. Install the spacer.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Spacer

4. Install the snap ring on the mainshaft.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Snap Ring

   2 - Clutch Drum/Drive Sprocket

5. Install the high/low range gear onto the mainshaft.

   Courtesy of CHRYSLER GROUP, LLC

   1 - High/Low Range Gear

ASSEMBLY OF THE SHIFT SHAFT ASSEMBLY 

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

   Courtesy of CHRYSLER GROUP, LLC

   1 - Shift Cam

2. Install the spacer.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Spacer

3. Install the high/low shift fork on the shift shaft.

   Courtesy of CHRYSLER GROUP, LLC

   1 - High/Low Shift Fork

4. Assemble the shift shaft assembly and the mainshaft assembly on the bench.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Mainshaft/Clutch Assembly

   2 - Shift Shaft Assembly

ASSEMBLY OF THE PLANETARY ASSEMBLY 

1. Install the lower thrust washer.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Lower Thrust Washer

2. Install the input gear.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Input Gear

3. Install the upper thrust washer.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Upper Thrust Washer

4. Install the carrier lock plate.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Lock Plate

5. Install the snap ring.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Snap Ring

ASSEMBLY OF SHAFTS AND HOUSING 

1. If the annulus gear was removed, install the annulus gear into the case half and install snap ring.
2. Install the planetary gear into the case half.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Annulus Gear

   2 - Planetary Gear Assembly

   3 - Snap Ring

3. 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.

4. 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.

5. If necessary, using (special tool #9672, Installer, Seal) with the (special tool #C-4171, Driver Handle, Universal), install front output shaft seal.
6. If necessary, using (special tool #9672, Installer, Seal) with the (special tool #C-4171, Driver Handle, Universal), install rear output seal.
7. Install the front output shaft.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Front Output Shaft

8. Install the snap ring.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Front Output Shaft

   2 - Snap Ring

9. 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.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Center Hub of Gear (Tall Side)

10. Install the high/low range gear on the lower portion of the mainshaft assembly.

    Courtesy of CHRYSLER GROUP, LLC

    1 - High/Low Range Gear

11. Assemble the shift shaft assembly and the mainshaft assembly together on the bench.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Mainshaft/Clutch Assembly

    2 - Shift Shaft Assembly

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

    Courtesy of CHRYSLER GROUP, LLC

    1 - Colored Chain Link

13. Simultaneously install the mainshaft assembly, shift shaft assembly and chain into the front case half.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Shift Shaft Assembly

    2 - Mainshaft/Clutch Assembly

    3 - Chain

14. Verify the chain and shafts are in completely and aligned correctly.
15. Install the spacer on the shift shaft if not already installed with the shift shaft assembly.

    Courtesy of CHRYSLER GROUP, LLC

16. 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.
17. Install the oil pump onto the mainshaft.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Shift Shaft Rear Bearing

    2 - Worm Gear

    3 - Oil Pump Tube

    4 - Oil Pump

18. Install the oil pump tube and magnet.
    NOTE:

    The magnet should sit under the oil pump tube pickup in the housing.

19. Install the worm gear on the shift shaft.
    NOTE:

    The worm gear should be installed with the concave side facing up.

20. Install the shift shaft rear bearing.
21. 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.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Spacer

    2 - Tabs (should be flat with the side facing up on the spacer)

22. Apply a 1/4" bead of Mopar® RTV to the rear case half mating surface.
23. 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.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Locating Dowels

    2 - Rear Case Half

    3 - Front Case Half

24. 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.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Worm Shaft

25. Install the case bolts.
26. If necessary, using the (special tool #2076700210, Installer, Input Shaft Seal), install input shaft seal.
27. 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.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Shift Motor Mounting Bolts

    2 - Transfer Case Shift Motor

    3 - Transfer Case Position Sensor Bolts

    4 - Transfer Case Position Sensor

28. Install the shift motor.
    NOTE:

    Verify the shift motor position and the sector shaft orientation are aligned.

29. Install new shift motor mounting bolts.
30. Install the transfer case position sensor.
31. Install the transfer case position sensor bolts.
32. Install the output flange on the rear output shaft.
33. Install the output flange spline seal.
34. Install the output flange nut.
35. Install the transfer case. Refer to MPT3028C TRANSFER CASE, REMOVAL AND INSTALLATION .