4:1 Rock-TRAC: Notes

DISASSEMBLY

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1 - Transfer Case Position Sensor

Remove the transfer case position sensor.

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1 - Flange Holder Tool

2 - Bolts

3 - Flange
Install two bolts partially in the propeller shaft companion flange, 180° from each other.

Install the rectangular end of the (special tool #C-3281, Holder, Flange) 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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1 - Transfer Case

2 - Flange

3 - Flange Puller

Using the (special tool #C-452, Puller, Companion Flange) remove the companion flange from the assembly.
Using the same procedure as the companion flange, remove the main shaft output flange.
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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1 - Transfer Case Bolts
Remove the transfer case bolts.
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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1 - Wood Block

2 - Rear Transfer Case Half
Remove the case by disengaging the rear of the case from the alignment dowels.

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1 - Oil Pump

2 - Oil Pump Pick-up Tube
Remove the oil pump and the oil pump pick-up tube.

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1 - Snap Rings

2 - Chain and Sprockets
Remove and DISCARD the snap-rings from each sprocket and remove the chain and sprockets by lifting both sprockets off of the shafts equally.

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1 - Detent Plug
Remove the detent plug with spring and plunger.

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1 - Main Shaft

2 - Shift Fork
Remove the main shaft and the shift fork and rail from the transfer case.
Remove the output shaft.

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1 - Snap Ring

2 - Synchronizer

Remove and DISCARD the snap ring and remove the synchronizer from the main shaft.

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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1 - Shift Rail

2 - Range Fork

3 - Input Gear

Remove the range fork assembly with the input gear.

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1 - SECTOR SUPPORT

2 - FRONT CASE

3 - SECTOR SHAFT

Remove the shift sector support.

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1 - SHIFT SECTOR
Remove shift sector.

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1 - Extension Housing Bolts
Remove the extension housing bolts.

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1 - Extension Housing
Remove the extension housing from the case.

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1 - Annulus Ring Gear

2 - Case
Remove the annulus ring gear from the case.
Clean the case halves.

ASSEMBLY

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.

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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1 - Output Flange

2 - Synchronizer

3 - Main Shaft

Using the output flange as a stand, install the synchronizer onto the main shaft.

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1 - Snap Ring

2 - Synchronizer
Install the NEW snap ring for the synchronizer onto the main shaft.

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1 - Annulus Ring Gear

2 - Case
Install the annulus ring gear into the case.
Clean the extension housing mating surfaces with brake cleaner or equivalent and wipe with a lint free shop cloth.
Place a 1/4" bead of Mopar® RTV sealant around the extension housing.

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1 - Extension Housing
Install the extension housing into the case.

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1 - Extension Housing Bolts

Install the extension housing bolts in a criss-cross pattern to the proper torque specification.

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1 - Shift Rail

2 - Range Fork

3 - Input Gear

Install the range fork, shift rail and the input gear into the case.

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1 - SHIFT SECTOR

Lubricate sector shaft with transmission fluid and install shift sector in case. Position slot in sector so it will be aligned with shift fork pin when shift forks are installed.

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1 - SECTOR SUPPORT

2 - FRONT CASE

3 - SECTOR SHAFT

Install the shift sector support.

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1 - Snap Rings

2 - Chain and Sprockets
Install the output shaft into the case and install the chain and sprockets with the blue link facing upward.

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1 - Snap Rings
Install the snap rings on both sprockets. If the snap rings are over extended or loose, replace them with NEW snap rings.

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1 - Oil Pump

2 - Oil Pump Pick-up Tube
Install the oil pump and pick up tube. Verify the pick up tube is seated in the slot in the case half.
Wipe the case half mating surfaces and place a 1/4" bead of Mopar® sealer on one case half.

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1 - Wood Block

2 - Rear Transfer Case Half
Install the case halves together, ensuring they are fully seated. Tighten the bolts in a criss-cross pattern to the proper torque specification.

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1 - Rear Output Flange Nut

2 - Rear Output Flange
Install the front and rear output flanges and the flange nuts. Tighten the nuts to the proper torque specification.

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1 - Transfer Case Position Sensor
Install the transfer case position sensor.
NOTE:
Inspect the transfer case position sensor O-ring for damage before installing the transfer case position sensor.
Install the transfer case. Refer to REMOVAL AND INSTALLATION .

TORQUE SPECIFICATIONS