Disassembly And Assembly: Rock-TRAC: Notes

WARNING: This page is about a different variant/trim than selected.

DISASSEMBLY

GC0182306

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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
Remove both output flanges. Install two bolts partially into the propeller shaft companion flange, 180° from each other.

Install the rectangular end of Flange Holder (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

Use Remover (special tool #C-452, Puller, Companion Flange) to remove the companion flange.
Remove the seal washer from the front output shaft. Discard the washer as it must not be reused.

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1 - Shift Motor

2 - Shift Motor Bolts
Remove the three shift motor bolts from the shift motor.

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1 - Shift Motor
Remove the shift motor.

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1 - Range Lever Bolt
Remove the bolt that attaches the range lever to the sector shaft. Then move the sector shaft to the neutral position and remove the range lever from the shaft.
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 case bolts.
Loosen the case halves with a pry tool to break the sealer bead. Insert the tool in the slot at each end of the case.

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1 - Wood Block

2 - Rear Transfer Case Half
Unseat the rear case from the alignment dowels and remove the case.

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1 - Oil Pump

2 - Oil Pump Pick-up Tube
Remove the oil pump with the oil pump pickup tube.

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1 - Magnet
Remove the magnet from the pocket that the oil pump pickup tube is seated in and thoroughly clean the magnet.

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1 - Oil Sump
Remove the oil sump from the case.

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1 - Chain

2 - Main Shaft Sprocket Assembly
Remove the chain and the main shaft sprocket assembly from the case.

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1 - Output Shaft Assembly

Remove the output shaft assembly from the case.

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1 - Input Gear

2 - Range Fork

3 - Range Fork Located in Selector Plate

Remove the range fork assembly with the input gear.
Remove the input shaft seal to access the planetary gear assembly snap ring
Remove the snap ring retaining the planetary gear assembly.

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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

If equipped with a removable annulus ring gear, remove the annulus ring gear from the case.

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1 - Ball Joint Remover/Installer Tool

2 - Output Shaft Assembly

3 - Snap Ring

With the output shaft assembly supported in a press, compress the clutch assembly enough using (special tool #9964, Remover/Installer, Ball Joint) to remove the output snap ring.

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1 - Shim
Remove the transfer case shim from the output thrust washer.

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1 - Thrust Washer
Remove the thrust washer from the upper apply cam.

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1 - Thrust Bearing
Remove the thrust bearing from the upper apply cam.

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1 - Upper Apply Cam

2 - Transfer Case Oil Sump Receiving Plate
Remove the upper apply cam, with the transfer case oil sump receiving plate, from the output shaft.

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1 - Ball Bearings

2 - Retaining Ring
Remove the ball bearings with the retaining ring from the apply cam.
NOTE:
Note the orientation of the opening on the retaining ring for reassembly.

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1 - Lower Apply Cam
Remove the lower apply cam from the output shaft.

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1 - Apply Plate
Remove the apply plate from the output shaft.

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1 - Spring Plate

2 - Tab Orientation
Remove the spring plate from the output shaft.
NOTE:
Note the orientation of the tabs when removing the spring plate.

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1 - Oil Deflector
Remove the oil deflector from the output shaft.

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1 - Clutch Drum Assembly
Remove the clutch drum assembly from the output shaft.

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1 - Clutch Drum Spacer
Remove the clutch drum spacer from the output shaft.

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1 - Driven Sprocket
Remove the driven sprocket from the output shaft.

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1 - Thrust Bearing
Remove the thrust bearing from the output shaft.

ASSEMBLY

Thoroughly clean both case halves and the mating surfaces.
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 - Thrust Bearing
Install the thrust bearing to the output shaft.

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1 - Driven Sprocket
Install the driven sprocket to the output shaft.

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1 - Clutch Drum Spacer
Install the clutch drum spacer to the output shaft.

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1 - Clutch Drum Assembly
Install the clutch drum assembly to the output shaft.

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1 - Oil Deflector
Install the oil deflector to the output shaft.

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1 - Spring Plate

2 - Tab Orientation
Install the spring plate to the output shaft.
NOTE:
Note the orientation of the tabs when installing the spring plate.

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1 - Apply Plate
Install the apply plate to the output shaft.

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1 - Lower Apply Cam
Install the lower apply cam to the output shaft.

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1 - Ball Bearings

2 - Retaining Ring
Install the ball bearings with the retaining ring into the lower apply cam.
NOTE:
Verify the orientation of the retaining ring to the gear teeth on the apply cam before reassembly.

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1 - Upper Apply Cam

2 - Transfer Case Oil Sump Receiving Plate
Install the upper apply cam with the transfer case oil sump receiving plate to the output shaft.

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1 - Thrust Bearing
Install the thrust bearing to the upper apply cam.

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1 - Thrust Washer
Install the thrust washer to the upper apply cam.

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1 - Shim

Install the transfer case shim to the output thrust washer.

GC0182106

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1 - Ball Joint Remover/Installer Tool

2 - Output Shaft Assembly

3 - Snap Ring

With the output shaft assembly supported in a press, compress the clutch assembly enough using (special tool #9964, Remover/Installer, Ball Joint) to install the output snap ring on the output shaft.

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1 - Annulus Ring Gear

2 - Case
If equipped with a removable annulus ring gear, 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 inch 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.

GC0183453

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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 - Output Shaft Assembly
Install the output shaft assembly into the case.

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1 - Chain

2 - Main Shaft Sprocket Assembly
Assemble the chain on the main shaft sprocket with the blue link facing up. Install the chain with the main shaft around the output driven sprocket and into the case.

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1 - Oil Sump
Install the oil sump into the receiving plate.

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1 - Magnet
Install the magnet into the case pocket.

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1 - Oil Pump Pick-up Tube O-ring
Inspect the oil pump pickup tube O-ring for damage, if damaged, replace the O-ring before installing the oil pump.

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1 - Oil Pump

2 - Oil Pump Pick-up Tube
Install the oil pump with the oil pump pickup tube on the output shaft.
Clean both case half 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. Place a 1/4 inch 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, make sure they are fully seated in the locating pins.

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1 - Transfer Case Bolts
Tighten the bolts in a crisscross pattern to the proper torque specification.

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1 - Seal Installer Tool

2 - Driver Handle
Using (special tool #2053900210, Installer, Seal Input Shaft) and (special tool #C-4171, Driver Handle, Universal), install the NEW front input shaft seal.

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1 - Rear Output Flange Nut

2 - Rear Output Flange
Install the front and rear output flanges with NEW 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.

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1 - Range Lever Bolt
Install the range lever bolt into the sector shaft.
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 as it was removed.

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1 - Shift Motor
Install the shift motor.

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1 - Shift Motor

2 - Shift Motor Bolts
Install the shift motor bolts.

TORQUE SPECIFICATIONS