Transfer Case MPT3028C: Notes

REMOVAL 

1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
2. Remove the transmission belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION .
3. Support the transfer case and transmission.
4. Remove the transfer case skid plate. Refer to PLATE, SKID, REMOVAL AND INSTALLATION .
5. Remove the exhaust muffler resonator. Refer to 2.0L, MUFFLER, EXHAUST, REMOVAL AND INSTALLATION or 3.6L, MUFFLER, EXHAUST, REMOVAL AND INSTALLATION or 5.7L, MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
6. Remove the transmission crossmember. Refer to CROSSMEMBER, REMOVAL AND INSTALLATION .
7. Mark the front driveshaft and transfer case flange for reassembly alignment.
   CAUTION:

   Never allow driveshaft to hang unsupported while connected to Power Transfer Unit (PTU), rear driveline module or front axle flanges. If driveshaft is hung unsupported, damage may occur to joint or boot from over-angulation.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Driveshaft To Flange Bolts

   2 - Driveshaft

8. Remove and DISCARD  the front driveshaft to transfer case flange bolts. Separate the front driveshaft from the flange. Push the shaft in toward the front differential, support and set aside.
9. Mark the rear driveshaft and transfer case flange for reassembly alignment.
   CAUTION:

   Do not allow the driveshaft to hang from the vehicle unsupported. Damage may occur to the joint, boot, and center bearing from over-angulation.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Driveshaft To Flange Bolts

10. Support the driveshaft near the center bearing.
11. Remove the exhaust hangers.

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    1 - Exhaust Hanger Bolts

    2 - Exhaust Hangers

12. Remove and DISCARD  the rear driveshaft center support bearing bolts and remove the exhaust heat shield.

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    1 - Rear Driveshaft Center Support Bearing Bolts

    2 - Exhaust Heat Shield

13. Remove and DISCARD  the rear driveshaft to transfer case flange bolts. Separate the rear driveshaft from the flange, support and set aside.

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    1 - Driveshaft To Flange Bolts

14. Remove the shift motor cover bolts and cover.

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    1 - Shift Motor M8 Cover Bolt

    2 - Shift Motor M10 Cover Bolts

15. PHEV vehicle only, remove the transfer case bending damper.
16. Disconnect the transfer case shift motor wire harness connector.

    1 - Transfer Case Shift Motor Wire Harness Connector

    2 - Transfer Case Position Sensor Wire Harness Connector

17. Disconnect the transfer case position sensor wire harness connector.

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    1 - Transfer Case to Transmission Bolts (Right Side)

18. Remove the left and right side transfer case to transmission bolts.

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    1 - Transfer Case to Transmission Bolts (Left Side)

19. Remove the transfer case from the vehicle.

INSTALLATION 

Follow the removal procedure in reverse for general reassembly of the components on the vehicle. The steps listed below are calling out specific procedures that should be followed during installation.

• Lightly grease the output shaft splines of the transmission.
• During installation of the driveshafts, align the previously created marks on the driveshafts with the marks on the output flanges.
• If necessary, fill the transfer case to the proper fluid level. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  NOTE:

  Do NOT  perform scan tool routines other than PROXI Alignment when installing a transfer case that came already equipped with a new DTCM.

• If a new transfer case is installed, use the scan tool to perform a PROXI Configuration Alignment routine.