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DESCRIPTION
DESCRIPTION
OPERATING RANGES
2WD HI.
4WD Lock.
Neutral.
4WD Low.
SHIFT MECHANISM
Operating ranges are selected with a dash mounted shift selector switch. The shift selector switch provides an
input to the Drive Train Control Module (DTCM) to indicate the driver's desire to change operating ranges. The
DTCM uses this input, along with the input from the transfer case mounted mode sensor and information from
the vehicle's CAN C bus, to determine if a shift is permitted. If the DTCM decides the shift is permitted, the
DTCM controls the shift motor, mounted to the exterior of the transfer case, to perform the shift.
OPERATION
OPERATION
The input gear is splined to the transmission output shaft. The input gear drives the mainshaft through the
planetary assembly and range sleeve. The front output shaft is operated by a drive chain that connects the shaft
to a drive sprocket on the mainshaft. Torque is transmitted through the input shaft to the drive sprocket
assembly. The torque is also transferred directly to the rear propeller shaft, to the front output shaft by the drive
chain when 4WD is selected. The oil pump circulates gear lube throughout the case to provide internal
lubrication and cooling.
DIAGNOSIS CHART
SPECIFICATIONS
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N.m Ft. Lbs. In. Lbs.
Plug, Drain/Fill 19 - 30 15 - 22 -
Bolt, Case Half 27 - 35 20 - 26 -
Breather 6.5 - 8.5 -- 60 - 72
Motor Mount and Bracket 8 - 11 -- 72 - 96
Motor Bracket (Bracket to
2.8 - 4 - 24 - 36
Motor)
Stud 22 - 27 - 192 - 240
Nuts, Mounting 41 30 -
Output Flange Nut 241 178 -
REMOVAL
REMOVAL
1. Raise vehicle.
2. Drain transfer case lubricant.
3. Mark front and rear propeller shafts for alignment reference.
4. If equipped, remove the Diesel Exhaust Fluid (DEF) tank. Refer to TANK, DIESEL EXHAUST
FLUID, REMOVAL .
DISASSEMBLY
DISASSEMBLY
1. Place the transfer case so that it can be drained of any remaining fluid and remove the fill (4) and drain
plugs (1).
2. Remove the four shift motor mounting bolts (2) and remove the shift motor (3).
11. Remove the mode shift fork, spring and sleeve (1) from the main shaft (2).
12. Remove the chain (2), the front out put gear (1) and main shaft gear (3) as an assembly.
NOTE: There are three alignment tabs and an oil pump hose pass through
incorporated into the support that prevent the structure from rotating once
installed.
13. Remove the center bearing support assembly (2) from the mainshaft (1).
Fig. 16: Shift Rail, Lower Shift Fork & Reduction Hub
Courtesy of CHRYSLER GROUP, LLC
18. Remove the shift rail (1), lower shift fork (3), and the reduction hub as an assembly.
19. Separate the lower shift fork (3) from the reduction hub (2).
20. Separate the lower shift fork (3) from the shift rail (1).
21. Lift the planetary carrier (1) straight up and out of the annulus gear (2).
22. Remove the carrier thrust bearing (1) from the center of the planetary (2).
25. Remove the front output shaft retaining ring (1) from the front output shaft (2).
26. Remove the front output shaft (1) from the front case half (2).
CLEANING
CLEANING
Clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases
and retainers with a scraper and 3M™ all purpose cleaner. Use compressed air to remove solvent residue from
oil feed passages in the case halves, retainers, gears, and shafts.
INSPECTION
INSPECTION
MAINSHAFT/SPROCKET/HUB INSPECTION
Inspect the splines on the hub and shaft and the teeth on the sprocket. Minor nicks and scratches can be
smoothed with an oilstone. However, replace any part that is damaged.
Check the contact surfaces in the sprocket bore and on the mainshaft. Minor nicks and scratches can be
smoothed with 320-400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe.
PLANETARY CARRIER
Examine the planetary carrier body (2) and pinion gears for wear or damage. Check the pinion gear thrust
washers on the pinon pins for damage. The carrier will have to be replaced as an assembly if the body, pinion
pins, or pinion gears are damaged.
Check the needle bearing in the carrier. Inspect the thrust bearing (1).
SHIFT FORK/HUBS/SLEEVES
Check condition of the shift fork and shift fork shift rail. Minor nicks on the shift rail can be smoothed with
320-400 grit emery cloth.
Check the reduction hub (1) for wear on the shift fork collar (2).
Check the teeth and splines of the reduction hub (1). Minor nicks can be dressed off with an oilstone. Replace
Inspect the extension housing seal and bushing. Replace both components if either show any sign of wear or
damage.
Inspect the shaft splines, sprocket teeth, and bearing surfaces. Minor nicks on the teeth can be smoothed with an
oilstone. Use 320-400 grit emery to smooth minor scratches on the shaft bearing surfaces. Rough threads on the
shaft can be chased if necessary. Replace the shaft if the splines are damaged, bearing surfaces are scored, or if
any sprocket teeth are cracked or broken.
Examine the drive chain and shaft bearings. Replace the chain and both sprockets if the chain is stretched,
distorted, or if any of the links bind. Replace the bearings if rough, or noisy.
Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces.
Also make sure the front case mounting studs are in good condition.
Check the front case mounting studs and vent tube. The tube can be secured with Loctite™ 271 or 680 if loose.
The stud threads can be cleaned up with a die if necessary. Also check condition of the fill/drain plug threads in
the rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired
with Helicoil® stainless steel inserts if required.
Examine the oil pump pickup parts. Replace the pump if any part appears to be worn or damaged. Do not
disassemble the pump as individual parts are not available. The pump is only available as a complete assembly.
The pickup screen, hose, and tube are the only serviceable parts and are available separately.
ASSEMBLY
ASSEMBLY
NOTE: When pressing bearings into case, be sure to properly support the underside of
the case half.
1. Using (special tool #9598, Installer, Seal) (1) and an Arbor Press, install the front output shaft bearing (2)
into the front case half (5).
2. Using (special tool #9754, Installer, Seal) (3) and an Arbor Press, install the input shaft bearing (4) into
the front case half (5).
NOTE: When pressing bearings into case, be sure to properly support the
underside of the case half.
3. Using (special tool #9598, Installer, Seal) (1) and an Arbor Press, install the rear output shaft bearing (2)
into the front case half (3).
NOTE: When pressing bearings into case, be sure to properly support the
underside of the case half.
4. Using (special tool #9598, Installer, Seal) (1) and an Arbor Press, install the front output shaft rear
support bearing (2) into the front case half (3).
5. Using (special tool #9754, Installer, Seal) (2) and (special tool #C-4171, Driver Handle, Universal) (1),
install input shaft seal (3).
6. Using (special tool #10174, Installer, Seal, Rear Output) (1), install front output shaft seal (2).
7. If transfer case is equipped with a flange, and using (special tool #9672, Installer, Seal) (2) with (special
tool #C-4171, Driver Handle, Universal) (1), install rear output seal (3).
8. If transfer case is equipped with a slip yoke, and using (special tool #9037, Installer, Dust Boot/Seal) (2)
with (special tool #C-4171, Driver Handle, Universal) (1), install the rear output seal (3).
9. Install the front output shaft (1) into the front housing (2).
10. Install the front output shaft retaining ring (1) on the front output shaft (2).
13. Install the carrier assembly (2) and thrust bearing (1).
Fig. 43: Shift Rail, Lower Shift Fork & Reduction Hub
Courtesy of CHRYSLER GROUP, LLC
14. Install the range shift fork (2), reduction hub and shift rail (1).
16. Install the shift assembly (1). Be sure the pin is seated in the case.
NOTE: There are three alignment tabs and an oil pump hose pass through
incorporated into the support that prevent the structure from rotating once
installed.
19. Install the center bearing support assembly (2) onto the main shaft (1).
NOTE: Chain and gears are patterned and must be installed correctly. Blue links
on the chain must be installed facing upward.
20. Install the chain (2), the front out put gear (1) and main shaft gear (3).
21. Install the mode shift fork (1) onto the main shaft (2)
31. Install the rear output flange nut (1) and tighten to 241 N.m (178 ft. lbs.), if equipped
32. Stake the nut to the shaft to prevent the nut from backing off, if equipped.
Fig. 57: Shift Motor, Mounting Bolt, Fill & Drain Plugs
Courtesy of CHRYSLER GROUP, LLC
INSTALLATION
INSTALLATION
SPECIAL TOOLS
SPECIAL TOOLS
FLUID
STANDARD PROCEDURE
Fig. 59: Shift Motor, Mounting Bolt, Fill & Drain Plugs
Courtesy of CHRYSLER GROUP, LLC
The fill (4) and drain (1) plugs are both in the rear case.
1. Raise vehicle.
2. Position drain pan under transfer case.
3. Remove drain and fill plugs and drain lubricant completely.
4. Install drain plug (1). Tighten plug to 19-30 N.m (15-22 ft. lbs.).
5. Remove drain pan.
6. Fill transfer case to bottom edge of fill plug opening with the correct fluid for the application. Refer to
CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
7. Install and tighten fill plug (2) to 19-30 N.m (15-22 ft. lbs.).
8. Wipe any excess fluid that may have spilled onto the exhaust.
9. Lower vehicle.
MOTOR, SHIFT
DESCRIPTION
DESCRIPTION
The shift motor consists of a permanent magnet D.C. motor with gear reduction to convert a high speed-low
torque device into a low speed-high torque device. The output of the device is coupled to a shaft which
internally moves the range fork that change the transfer case operating ranges. The shift motor uses a digital
encoder to monitor the shift motor position. The motor is rated at 20 amps maximum at 25° C (77° F) with 14
volts at the motor leads.
OPERATION
OPERATION
The transfer case shift motor responds to the Drive Train Control Module (DTCM) commands to move the
transfer case shift range fork, as required, to obtain the correct transfer case operating range indicated by the
instrument panel mounted selector switch. The motor only shifts between 1:1 ranges, 2.64:1 range, and neutral.
Switch changes between 2WD, 4WD LO and 4WD HI are assisted by the transfer case coil.
REMOVAL
REMOVAL
NOTE: The shift motor and sensor are one piece and are not to be disassembled.
Do not disassemble the shift motor and sensor as this will effect shift
motor and sensor functionality.
4. Separate the shift motor and mode sensor assembly from the transfer case.
INSTALLATION
INSTALLATION
NOTE: Verify that the shift motor position and sector shaft orientation are aligned.
It may be necessary to manually shift the transfer case if the shift motor
and sector shaft are not aligned.
3. Install the shift motor (1) onto the transfer case (2).
4. Install the shift motor and mode sensor assembly (1) onto the transfer case.
5. Install the bolts to hold the shift motor and mode sensor assembly onto the transfer case. Tighten the bolts
to 8-11 N.m (72-96 in. lbs.).
6. While holding the shift motor bracket tight against the shift motor, tighten the bracket to the transfer case
to 8-11 N.m (72-96 in. lbs.).
7. Tighten the shift motor bracket to the shift motor to 2.8-4 N.m (24-36 in. lbs.).
8. Engage the wiring connectors to the shift motor and sensor assembly.
9. Refill the transfer case as necessary with the correct fluid for the application. Refer to CAPACITIES
AND RECOMMENDED FLUIDS, DESCRIPTION .
10. Lower vehicle and verify transfer case operation.