Disassembly And Assembly: Select-TRAC: Notes

DISASSEMBLY 

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1. Remove the transfer case position sensor.

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   1 - Flange Holder Tool

   2 - Bolts

   3 - Flange

2. Remove both output flanges. Install two bolts partially into the propeller shaft companion flange, 180° from each other.
3. 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

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

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   1 - Harmonics Damper Bolts

   2 - Harmonics Damper

6. If equipped, remove the harmonics damper fasteners and remove the harmonics damper.

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   1 - Shift Motor

   2 - Shift Motor Bolts

7. Remove the three shift motor bolts from the shift motor.

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   1 - Shift Motor

8. Remove the shift motor.

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   1 - Range Lever Bolt

9. 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

10. Remove the case bolts.
11. Loosen the case halves with pry tool to break the sealer bead. Insert tool in slot at each end of case.

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    1 - Wood Block

    2 - Rear Transfer Case Half

12. 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

13. Remove the oil pump with the oil pump pick-up tube.

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    1 - Magnet

14. 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

15. Remove the oil sump from the case.

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    1 - Chain

    2 - Main Shaft Sprocket Assembly

16. Remove the chain and the main shaft sprocket assembly from the case.

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    1 - Output Shaft Assembly

17. 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

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

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    1 - Planetary Gear Set

21. Remove the planetary gear set.

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    1 - Ball Joint Remover/Installer Tool

    2 - Output Shaft Assembly

    3 - Snap Ring

22. 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

23. Remove the transfer case shim from the output thrust washer.

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    1 - Thrust Washer

24. Remove the thrust washer from the upper apply cam.

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    1 - Thrust Bearing

25. Remove the thrust bearing from the upper apply cam.

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    1 - Upper Apply Cam

    2 - Transfer Case Oil Sump Receiving Plate

26. 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

27. 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

28. Remove the lower apply cam from the output shaft.

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    1 - Apply Plate

29. Remove the apply plate from the output shaft.

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    1 - Spring Plate

    2 - Tab Orientation

30. 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

31. Remove the oil deflector from the output shaft.

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    1 - Clutch Drum Assembly

32. Remove the clutch drum assembly from the output shaft.

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    1 - Clutch Drum Spacer

33. Remove the clutch drum spacer from the output shaft.

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    1 - Driven Sprocket

34. Remove the driven sprocket from the output shaft.

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    1 - Thrust Bearing

35. Remove the thrust bearing from the output shaft.

ASSEMBLY 

1. Thoroughly clean both case halves and the mating surfaces.
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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   1 - Thrust Bearing

3. Install the thrust bearing to the output shaft.

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   1 - Driven Sprocket

4. Install the driven sprocket to the output shaft.

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   1 - Clutch Drum Spacer

5. Install the clutch drum spacer to the output shaft.

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   1 - Clutch Drum Assembly

6. Install the clutch drum assembly to the output shaft.

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   1 - Oil Deflector

7. Install the oil deflector to the output shaft.

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   1 - Spring Plate

   2 - Tab Orientation

8. 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

9. Install the apply plate to the output shaft.

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   1 - Lower Apply Cam

10. Install the lower apply cam to the output shaft.

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    1 - Ball Bearings

    2 - Retaining Ring

11. 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. The figure shown is the correct orientation.

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    1 - Upper Apply Cam

    2 - Transfer Case Oil Sump Receiving Plate

12. Install the upper apply cam with the transfer case oil sump receiving plate to the output shaft.

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    1 - Thrust Bearing

13. Install the thrust bearing to the upper apply cam.

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    1 - Thrust Washer

14. Install the thrust washer to the upper apply cam.

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    1 - Shim

15. Install the transfer case shim to the output thrust washer.

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    1 - Ball Joint Remover/Installer Tool

    2 - Output Shaft Assembly

    3 - Snap Ring

16. 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 - Planetary Gear Set

17. Install the planetary gear set into the annulus gear.

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    1 - Input Gear

    2 - Range Fork

    3 - Range Fork Located in Selector Plate

18. Assemble the input gear assembly together with the range fork and install them into the planetary carrier.

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    1 - Range Fork Located in Selector Plate

19. Make sure the tang on the range fork is seated in the notch on the selector plate.

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    1 - Output Shaft Assembly

20. Install the output shaft assembly into the case.

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    1 - Chain

    2 - Main Shaft Sprocket Assembly

21. 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

22. Install the oil sump into the receiving plate.

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    1 - Magnet

23. Install the magnet into the case pocket.

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    1 - Oil Pump Pick-up Tube O-ring

24. 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

25. Install the oil pump with the oil pump pickup tube on the output shaft.
26. 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

27. Install the rear case half making sure it is fully seated in the locating pins.

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    1 - Transfer Case Bolts

28. Tighten the case bolts in a criss-cross pattern to the proper torque specification.

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    1 - Seal Installer Tool

    2 - Driver Handle

29. 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

30. 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

31. Install the transfer case position sensor.

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    1 - Range Lever Bolt

32. 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

33. Install the shift motor.

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    1 - Shift Motor

    2 - Shift Motor Bolts

34. Install the three shift motor bolts.

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    1 - Harmonics Damper Bolts

    2 - Harmonics Damper

35. If equipped, position the harmonics damper.

TORQUE SPECIFICATIONS