4:1 Rock-TRAC: Notes

DISASSEMBLY 

1. Remove the transfer case position sensor.

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   1 - Transfer Case Position Sensor

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

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   1 - Flange Holder Tool

   2 - Bolts

   3 - Flange

3. Install the rectangular end of the special tool # C-3281, (Flange Holder) over the bolts to hold the companion flange stationary and remove the nut holding the companion flange to the output shaft.
4. Using the special tool # C-452, (Companion Flange Puller) remove the companion flange from the assembly.

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   1 - Transfer Case

   2 - Flange

   3 - Flange Puller

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.

7. Remove the transfer case bolts.

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   1 - Transfer Case Bolts

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

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   1 - Wood Block

   2 - Rear Transfer Case Half

10. Remove the oil pump and the oil pump pick-up tube.

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    1 - Oil Pump

    2 - Oil Pump Pick-up Tube

11. 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 - Snap Rings

    2 - Chain and Sprockets

12. Remove the detent plug with spring and plunger.

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    1 - Detent Plug

13. Remove the main shaft and the shift fork and rail from the transfer case.

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    1 - Main Shaft

    2 - Shift Fork

14. Remove the output shaft.
15. 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 - Snap Ring

    2 - Synchronizer

16. Remove the range fork assembly with the input gear.

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    1 - Shift Rail

    2 - Range Fork

    3 - Input Gear

17. Remove the shift sector support.

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    1 - SECTOR SUPPORT

    2 - FRONT CASE

    3 - SECTOR SHAFT

18. Remove shift sector.

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    1 - SHIFT SECTOR

19. Remove the extension housing bolts.

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    1 - Extension Housing Bolts

20. Remove the extension housing from the case.

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    1 - Extension Housing

21. Remove the annulus ring gear from the case.

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    1 - Annulus Ring Gear

    2 - Case

22. 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).
3. Using the output flange as a stand, install the synchronizer onto the main shaft.

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   1 - Output Flange

   2 - Synchronizer

   3 - Main Shaft

4. Install the NEW  snap ring for the synchronizer onto the main shaft.

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   1 - Snap Ring

   2 - Synchronizer

5. Install the annulus ring gear into the case.

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   1 - Annulus Ring Gear

   2 - Case

6. Clean the extension housing mating surfaces with brake cleaner or equivalent and wipe with a lint free shop cloth.
7. Place a 1/4" bead of Mopar® RTV sealant around the extension housing.
8. Install the extension housing into the case.

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   1 - Extension Housing

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

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   1 - Extension Housing Bolts

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

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    1 - Shift Rail

    2 - Range Fork

    3 - Input Gear

11. 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 - SHIFT SECTOR

12. Install the shift sector support.

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    1 - SECTOR SUPPORT

    2 - FRONT CASE

    3 - SECTOR SHAFT

13. 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

    2 - Chain and Sprockets

14. 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 - Snap Rings

15. Install the oil pump and pick up tube. Verify the pick up tube is seated in the slot in the case half.

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    1 - Oil Pump

    2 - Oil Pump Pick-up Tube

16. Wipe the case half mating surfaces and place a 1/4" bead of Mopar® sealer on one case half.
17. 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 - Wood Block

    2 - Rear Transfer Case Half

18. Install the front and rear output flanges and the flange nuts. Tighten the nuts to the proper torque specification.

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    1 - Rear Output Flange Nut

    2 - Rear Output Flange

19. Install the transfer case position sensor.
    NOTE:

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

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    1 - Transfer Case Position Sensor

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