Disassembly And Assembly: Command-TRAC: Notes

DISASSEMBLY 

1. Remove the transfer case position sensor.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Transfer Case Position Sensor

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

   Courtesy of CHRYSLER GROUP, LLC

   1 - Flange Holder Tool

   2 - Bolts

   3 - Flange

4. Using the special tool # C-452, (Companion Flange Puller) remove the companion flange from the assembly.

   Courtesy of CHRYSLER GROUP, LLC

   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.

   Courtesy of CHRYSLER GROUP, LLC

   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.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Wood Block

   2 - Rear Transfer Case Half

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

    Courtesy of CHRYSLER GROUP, LLC

    1 - Oil Pump

    2 - Oil Pump Pick-up Tube

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

    Courtesy of CHRYSLER GROUP, LLC

    1 - Snap Rings

    2 - Chain and Sprockets

12. Remove the detent plug with spring and plunger.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Detent Plug

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

    Courtesy of CHRYSLER GROUP, LLC

    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. 

    Courtesy of CHRYSLER GROUP, LLC

    1 - Snap Ring

    2 - Synchronizer

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

    Courtesy of CHRYSLER GROUP, LLC

    1 - Input Gear

    2 - Range Fork

    3 - Range Fork Located in Selector Plate

17. Remove the shift sector support.

    Courtesy of CHRYSLER GROUP, LLC

    1 - SECTOR SUPPORT

    2 - FRONT CASE

    3 - SECTOR SHAFT

18. Remove shift sector.

    Courtesy of CHRYSLER GROUP, LLC

    1 - SHIFT SECTOR

19. Remove the input shaft seal to access the planetary gear assembly snap ring
20. Remove the snap ring retaining the planetary gear assembly.
21. Remove the planetary gear set.
    NOTE:

    THE STANDARD MP1622 ANNULUS RING GEAR IS NOT REPLACEABLE, YOU MUST REPLACE THE CASE HALF. 

    Courtesy of CHRYSLER GROUP, LLC

    1 - Planetary Gear Set

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.

   Courtesy of CHRYSLER GROUP, LLC

   1 - Output Flange

   2 - Synchronizer

   3 - Main Shaft

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

   Courtesy of CHRYSLER GROUP, LLC

   1 - Snap Ring

   2 - Synchronizer

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

   Courtesy of CHRYSLER GROUP, LLC

   1 - Planetary Gear Set

7. Install the snap ring retaining the planetary gear assembly.
8. 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.

   Courtesy of CHRYSLER GROUP, LLC

   1 - SHIFT SECTOR

9. Install the shift sector support.

   Courtesy of CHRYSLER GROUP, LLC

   1 - SECTOR SUPPORT

   2 - FRONT CASE

   3 - SECTOR SHAFT

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

    Courtesy of CHRYSLER GROUP, LLC

    1 - Input Gear

    2 - Range Fork

    3 - Range Fork Located in Selector Plate

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

    Courtesy of CHRYSLER GROUP, LLC

    1 - Range Fork Located in Selector Plate

12. Holding the mode fork onto the synchronizer, while supporting the synchronizer from the bottom, guide the shift rail and the main shaft into their respective bores.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Mode Fork

    2 - Shift Rail

    3 - Main Shaft

13. Install the output shaft into the case and install the chain and sprockets with the blue link facing upward.

    Courtesy of CHRYSLER GROUP, LLC

    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.

    Courtesy of CHRYSLER GROUP, LLC

    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.

    Courtesy of CHRYSLER GROUP, LLC

    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.

    Courtesy of CHRYSLER GROUP, LLC

    1 - Wood Block

    2 - Rear Transfer Case Half

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

    Courtesy of CHRYSLER GROUP, LLC

    1 - Transfer Case Bolts

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

    Courtesy of CHRYSLER GROUP, LLC

    1 - Seal Installer Tool

    2 - Driver Handle

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

    Courtesy of CHRYSLER GROUP, LLC

    1 - Rear Output Flange Nut

    2 - Rear Output Flange

21. Install the transfer case position sensor.
    NOTE:

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

    Courtesy of CHRYSLER GROUP, LLC

    1 - Transfer Case Position Sensor

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