MP3023 Transfer Case - Service Information: Removal & Installation Dodge Durango III

INSTALLATION

1. Mount transfer case (1) on a transmission jack.
2. Secure transfer case to jack with chains.
3. Position transfer case under vehicle.
4. Align transfer case (1) and transmission (2) shafts and install transfer case onto transmission.
5. Install and tighten transfer case attaching bolts (3) to 41-49 N.m (30-36 ft. lbs.) torque.
6. Connect the transfer case vent hose to the transfer case.
7. Install the rear support cushion.
8. Install rear crossmember and skid plate, if equipped.
9. Remove transmission jack and support stand.
10. Connect front propeller shaft and install rear propeller shaft. Refer to «SHAFT, DRIVE, FRONT , INSTALLATION»(ref-465926-S33290621992012042300000) and «SHAFT, DRIVE, REAR , INSTALLATION»(ref-465926-S23102361482012042300000) .
11. Install the transfer case drain plug (2). Tighten plug to 20-34 N.m (15-25 ft. lbs.)
12. Fill transfer case with correct fluid. Check transmission fluid level. Refer to «STANDARD PROCEDURE»(ref-465986-S17844943482012042300000) . Correct as necessary.
13. Install the transfer case fill plug (1). Tighten the plug to 20-34 N.m (15-25 ft.lbs.).
14. Connect the shift motor and encoder electrical connectors.
15. Lower vehicle and verify transfer case shift operation.

Note. The air suspension system will auto-disable when lifted on a frame hoist, or when jacking one corner of the vehicle. The air suspension may attempt to change height slightly prior to switching to auto-disable. A manual disable is also available by pressing the "Up" and "Down" switches of the terrain select switch simultaneously for more that 5 seconds. The air suspension system will return to normal operation when the vehicle speed reaches 25 kph (15 mph).

REMOVAL

Note. New shift motor assemblies are shipped in the NEUTRAL position. If a new shift motor assembly must be installed, it will be necessary to shift the transfer case to the NEUTRAL position prior to motor installation.

1. Disengage the wiring harness electrical connector from the shift motor.
2. Remove the bolts holding the shift motor onto the transfer case.
3. Remove the shift motor from the transfer case.
4. Remove the o-ring seal from the shift motor.

Note. Before installing the shift motor onto the transfer case, make certain that the shift motor shaft aligns with the transfer case worm shaft accordingly.

1. Install a NEW shift motor o-ring seal onto the shift motor.
2. Install the shift motor onto the transfer case.
3. Install the shift motor bolts. Tighten the shift motor bolts to 13 N.m (9 ft. lbs.).
4. Install the electrical wiring harness connector onto the shift motor.

1. Remove the transfer case from the vehicle. Refer to «REMOVAL»(ref-465986-S23261807412012042300000) .
2. Remove the front input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.

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

1. Using Installer (special tool #9672, Installer, Seal) (2) and Handle (special tool #C-4171, Driver Handle, Universal) (1), install a new input shaft seal.
2. Install the transfer case into the vehicle. Refer to «INSTALLATION»(ref-465986-S22921501872012042300000) .
3. Check the transfer case fluid. Correct as necessary. Refer to «STANDARD PROCEDURE»(ref-465986-S17844943482012042300000) .

The front output shaft seal and wear sleeve cannot be serviced in the vehicle. The transfer case must be disassembled to remove the front output shaft assembly and seal.

1. Remove the rear propeller shaft. Refer to «SHAFT, DRIVE, FRONT , REMOVAL»(ref-465926-S08575329782012042300000) and «SHAFT, DRIVE, REAR , REMOVAL»(ref-465926-S36963294482012042300000) .
2. Using Holder (special tool #C-3281, Holder, Flange) (1), remove the rear companion flange (2) nut.
3. Remove the rear output shaft flange from the output shaft. If necessary, use a suitable 2 or 3 jaw puller to remove the output shaft flange.
4. Remove the rear output shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
5. Remove the rear cover bolts and the rear cover from the transfer case.

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

1. Install a new rear output shaft seal into the rear cover with Driver Handle (special tool #C-4171, Driver Handle, Universal) and inverted Installer (special tool #C-4210, Installer, Seal).
2. Install the rear output shaft flange onto the output shaft.
3. Using Holder (special tool #C-3281, Holder, Flange) (1), install the rear companion flange (2) nut. Tighten the nut to 122-176 N.m (90-130 ft.lbs.).
4. Install the rear propeller shaft. Refer to «SHAFT, DRIVE, FRONT , INSTALLATION»(ref-465926-S33290621992012042300000) and «SHAFT, DRIVE, REAR , INSTALLATION»(ref-465926-S23102361482012042300000) .
5. Check the transfer case fluid level. Refer to «STANDARD PROCEDURE»(ref-465986-S17844943482012042300000) . Correct as necessary.

1. Remove the wiring harness electrical connector from the encoder.
2. Remove the screws securing the encoder to the rear transfer case housing.
3. Remove the encoder from the transfer case.

1. Align arrow (1) on the encoder shaft with alignment mark (2) prior to installing the encoder. NOTE: Before installing the encoder onto the transfer case, be certain to align the encoder shaft to the shift shaft and the dowel on the encoder to the hole in the case accordingly.
2. Install the encoder onto the rear transfer case housing.
3. Install the encoder screws. Tighten the screws to 5-8 N.m (44-71 in.lbs.).
4. Install the electrical wiring harness connector onto the encoder.

Scheme 80

Electric shifting between AWD Auto and Low is accomplished with a console-mounted switch. A push button is used to shift to Neutral mode.

1. All Wheel Drive Auto (1).
2. Low Range (2).
3. Control Knob (3).
4. Neutral button (4).