MP2010 Transfer Case - Service Information: Overhaul Dodge Durango III

ASSEMBLY

Note. Lubricate all seals with MOPAR® ATF+4 prior to installation.

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1. Clean any sealer from the case halves.
2. Using seal installer (special tool #8802, Installer, Seal) (1), install rear output seal (2) into the case half (3).
3. Using seal installer (special tool #8802, Installer, Seal) (1), install front output seal into case half (2).
4. Using seal installer (special tool #9672, Installer, Seal) (2) with drive handle (special tool #C-4171, Driver Handle, Universal) (1), install input shaft seal (3) into case half (4).
5. Install the snap ring (1).
6. Install wave spacer (2) on input shaft (1).
7. Install bearing (3) onto input shaft (1) and press into place.
8. Install snap ring (1) on input shaft (2).
9. Install input shaft bearing spacer (1) into the case half (2).
10. Install input shaft and bearing assembly (1) into case half (2) and press into place. NOTE: Both output shaft bearings have a tapered inner race that must be installed toward the seal.
11. Properly support case half in press, and using (special tool #9227, Gauge, Pinion Height) (1), press bearing into case (2). (Front output bearing shown in illustration, rear output bearing uses the same tool and process.)
12. Install the front output shaft. Start the shaft into the bearing by hand with a rocking action to get the snap ring started into the bearing.
13. Seat the front output shaft (3) into the bearing and case (4) using installer (special tool #C-4657, Installer, Seal) (2) and Handle (special tool #C-4171, Driver Handle, Universal) (1).
14. Install the rear output shaft. Start the shaft into the bearing by hand with a rocking action to get the snap ring started into the bearing.
15. Seat the rear output shaft (3) into the bearing and case (4) using installer (special tool #C-4657, Installer, Seal) (2) inverted and Handle (special tool #C-4171, Driver Handle, Universal) (1).
16. Install the thrust washer (2) on the input shaft (3) with the four groves upward and install snap ring (1). NOTE: There is a blue link on one side of the chain. This blue link MUST be installed facing upward.
17. Install the chain (1) and sprockets (2, 3) on the input shaft and front output shaft.
18. Install the oil slinger (2) differential (1).
19. Apply a small amount of RTV to the magnet to hold in place and install.
20. After installing differential, turn so the oil slinger will hold differential in place during assembly of the case halves.
21. Apply bead of Mopar® Gasket Maker, or equivalent, to one of the mating surfaces of the front or rear housing.
22. Install the rear case half. While installing the case half, rotate the output shaft flange back and forth to engage the input shaft into the differential.
23. Install case bolts and tighten housing bolts in a crisscross pattern to 27 N.m (20 ft.lbs.).