Disassembly And Assembly: Select-TRAC: Notes

DISASSEMBLY 

1. Remove the transfer case position sensor.

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   1 - Transfer Case Position Sensor

2. Remove both output flanges. Install two bolts partially into 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. Use Special Tool # C-452, (Companion Flange Puller) to remove the companion flange.

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   1 - Transfer Case

   2 - Flange

   3 - Flange Puller

5. Remove the seal washer from the front output shaft. Discard the washer as it must not be reused.
6. If equipped, remove the harmonics damper fasteners and remove the harmonics damper.

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   1 - Harmonics Damper Bolts

   2 - Harmonics Damper

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

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   1 - Shift Motor Bolts

   2 - Shift Motor

8. Remove the shift motor.

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   1 - Shift Motor

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 - Range Lever Bolt

10. Remove the case bolts.

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    1 - Transfer Case Bolts

11. Loosen the case halves with pry tool to break the sealer bead. Insert tool in slot at each end of case.
12. Unseat the rear case from the alignment dowels and remove the case.

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    1 - Wood Block

    2 - Rear Transfer Case Half

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

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    1 - Oil Pump

    2 - Oil Pump Pick-up Tube

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 - Magnet

15. Remove the oil sump from the case.

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    1 - Oil Sump

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

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    1 - Chain

    2 - Main Shaft Sprocket Assembly

17. Remove the output shaft assembly from the case.

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    1 - Output Shaft Assembly

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

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    1 - Input Gear

    2 - Range Fork

    3 - Range Fork Located in Selector Plate

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.

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    1 - Ball Joint Remover/Installer Tool

    2 - Output Shaft Assembly

    3 - Snap Ring

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    1 - Planetary Gear Set

22. With the output shaft assembly supported in a press, compress the clutch assembly enough using special tool # 9964, (Ball Joint Remover/Installer) to remove the output snap ring.
23. Remove the transfer case shim from the output thrust washer.

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    1 - Shim

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

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    1 - Thrust Washer

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

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    1 - Thrust Bearing

26. Remove the upper apply cam, with the transfer case oil sump receiving plate, from the output shaft.

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    1 - Upper Apply Cam

    2 - Transfer Case Oil Sump Receiving Plate

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 - Ball Bearings

    2 - Retaining Ring

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

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    1 - Lower Apply Cam

29. Remove the apply plate from the output shaft.

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    1 - Apply Plate

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 - Spring Plate

    2 - Tab Orientation

31. Remove the oil deflector from the output shaft.

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    1 - Oil Deflector

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

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    1 - Clutch Drum Assembly

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

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    1 - Clutch Drum Spacer

34. Remove the driven sprocket from the output shaft.

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    1 - Driven Sprocket

35. Remove the thrust bearing from the output shaft.

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    1 - Thrust Bearing

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).
3. Install the thrust bearing to the output shaft.

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   1 - Thrust Bearing

4. Install the driven sprocket to the output shaft.

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   1 - Driven Sprocket

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

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   1 - Clutch Drum Spacer

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

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   1 - Clutch Drum Assembly

7. Install the oil deflector to the output shaft.

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   1 - Oil Deflector

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 - Spring Plate

   2 - Tab Orientation

9. Install the apply plate to the output shaft.

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   1 - Apply Plate

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

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    1 - Lower Apply Cam

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 - Ball Bearings

    2 - Retaining Ring

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

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    1 - Upper Apply Cam

    2 - Transfer Case Oil Sump Receiving Plate

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

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    1 - Thrust Bearing

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

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    1 - Shim

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    1 - Thrust Washer

15. Install the transfer case shim to the output thrust washer.
16. With the output shaft assembly supported in a press, compress the clutch assembly enough using special tool # 9964, (Ball Joint Remover/Installer) to install the output snap ring on the output shaft.

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    1 - Ball Joint Remover/Installer Tool

    2 - Output Shaft Assembly

    3 - Snap Ring

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

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    1 - Planetary Gear Set

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

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    1 - Input Gear

    2 - Range Fork

    3 - 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 - Range Fork Located in Selector Plate

20. Install the output shaft assembly into the case.

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    1 - Output Shaft 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 - Chain

    2 - Main Shaft Sprocket Assembly

22. Install the oil sump into the receiving plate.

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    1 - Oil Sump

23. Install the magnet into the case pocket.

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    1 - Magnet

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 Pick-up Tube O-ring

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

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    1 - Oil Pump

    2 - Oil Pump Pick-up Tube

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

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    1 - Wood Block

    2 - Rear Transfer Case Half

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

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    1 - Transfer Case Bolts

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

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    1 - Seal Installer Tool

    2 - Driver Handle

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 - Rear Output Flange Nut

    2 - Rear Output Flange

31. Install the transfer case position sensor.

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    1 - Transfer Case Position Sensor

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 - Range Lever Bolt

33. Install the shift motor.

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    1 - Shift Motor

34. Install the three shift motor bolts.

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    1 - Shift Motor

    2 - Shift Motor Bolts

35. If equipped, position the harmonics damper.

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    1 - Harmonics Damper Bolts

    2 - Harmonics Damper