Disassembly And Assembly: Command-TRAC

DISASSEMBLY 

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1. Remove the transfer case position sensor (1).

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2. Install two bolts (2) partially in the propeller shaft companion flange (3), 180° from each other.
3. Install the rectangular end of the (special tool #C-3281, Holder, Flange) (1) over the bolts to hold the companion flange stationary and remove the nut holding the companion flange to the output shaft.

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4. Using the (special tool #C-452, Puller, Companion Flange) (3) remove the companion flange (2) from the assembly (1).
5. Using the same procedure as the companion flange, remove the main shaft output flange.
6. Remove the range lever to selector shaft bolt.
   NOTE:

   Be sure to note the orientation of the range lever (lever up or down) so that it may be re-installed in the same direction.

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7. Remove the transfer case bolts (1).
8. Using an acceptable pry tool inserted in the slot at each end of the transfer case, loosen the transfer case halves to break the sealer bead.

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9. Remove the case by disengaging the rear of the case (2) from the alignment dowels.

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10. Remove the oil pump (1) and the oil pump pick-up tube (2).

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11. Remove the snap-rings (1) from each sprocket (2) and remove the chain and sprockets (2) by lifting both sprockets off of the shafts equally.

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12. Remove the detent plug (1) with spring and plunger.

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13. Remove the mainshaft (1) and the shift fork and rail (2) from the transfer case.
14. Remove the output shaft.

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15. Remove and DISCARD  the snap ring (1) and remove the synchronizer (2) from the mainshaft.
    NOTE:

    Grasp the synchronizer at both the top and bottom when installing or removing the synchronizer. Failure to hold the synchronizer together may allow the outer ring of the synchronizer to drop, allowing the small springs, ball bearings, and slides to fall out and scatter. 

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16. Remove the range fork assembly (2) with the input gear (1).

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17. Remove the planetary gear set.
    NOTE:

    THE MP1622 ANNULUS RING GEAR IS NOT REPLACEABLE, YOU MUST REPLACE THE CASE HALF. THE MP1622-OR ANNULUS RING GEAR IS REPLACEABLE WITHOUT REPLACING THE CASE HALF. 

18. Clean the case halves.

ASSEMBLY 

1. Clean both case halves and mating surfaces using brake cleaner or similar. Make sure all of the old sealer is removed and the surface is free of any oils or debris.
2. Replace any bearings in the case halves that are spalled, damaged, or have been subjected to highly contaminated fluid (metal contamination from catastrophic failure).

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3. Using the output flange (1) as a stand, install the synchronizer (2) onto the mainshaft (3).

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4. Install the NEW  snap ring (1) for the synchronizer (2) onto the main shaft.
5. If equipped with removable annulus ring gear, install the annulus ring gear into the case half. Install the annulus ring gear snap ring, be sure to fully seat the snap ring.

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6. Install the planetary gear set (1) into the annulus gear.

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7. Assemble the input gear assembly (1) together with the range fork (2) and install them into the planetary carrier.

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8. Make sure the tang (1) on the range fork is seated in the notch on the selector plate.

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9. Holding the mode fork (1) onto the synchronizer, while supporting the synchronizer from the bottom, guide the shift rail (2) and the mainshaft (3) into their respective bores.

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10. Install the output shaft into the case and install the chain and sprockets (2) with the blue link facing upward.

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11. Install the snap rings (1) on both sprockets. If the snap rings are over extended or loose, replace them with NEW  snap rings.

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12. Install the oil pump (1) and pick up tube (2). Verify the pick up tube (2) is seated in the slot in the case half.
13. Wipe the case half mating surfaces and place a 1/4" bead of Mopar® sealer on one case half.

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14. Install the case halves together, ensuring they are fully seated. Tighten the bolts in a criss-cross pattern to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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15. Install the front and rear output flanges (2) and the flange nuts (1). Tighten the nuts to the proper specifications. Refer to TORQUE SPECIFICATIONS .

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16. Install the transfer case position sensor (1) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS .
    NOTE:

    Inspect the transfer case position sensor O-ring for damage before installing the transfer case position sensor. 

17. Install the transfer case. Refer to REMOVAL AND INSTALLATION .