MP3023 Transfer Case - Service Information: Specifications Dodge Durango III

SPECIFICATIONS

MP3023 FLUID

TORQUE

Scheme 29

Scheme 30

1. Shift transfer case into NEUTRAL.
2. Raise vehicle. 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).
3. Remove transfer case fill plug (1) and drain plug (2) to drain transfer case lubricant.
4. Support transmission (3) with jack stand.
5. Remove rear crossmember and skid plate, if equipped.
6. Remove the rear support cushion. CAUTION: Do not allow propeller shafts to hang at attached end. Damage to joint can result.
7. Disconnect front propeller shaft from transfer case at companion flange. Remove rear propeller shaft from vehicle. Refer to «SHAFT, DRIVE, FRONT , REMOVAL»(ref-465926-S08575329782012042300000) and «SHAFT, DRIVE, REAR , REMOVAL»(ref-465926-S36963294482012042300000) .
8. Disconnect the transfer case shift motor and mode sensor electrical connector.
9. Disconnect transfer case vent hose.
10. Support transfer case (1) with transmission jack.
11. Secure transfer case to jack with chains.
12. Remove bolts (3) attaching transfer case to transmission (2).
13. Pull transfer case and jack rearward to disengage transfer case.
14. Remove transfer case from under vehicle.

Scheme 31

Note. If the transfer case assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the Scan Tool.

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

1. Place the transfer case in a shallow pan and remove the fill and drain plugs to drain the remainder of the fluid.
2. Using Holder (special tool #C-3281, Holder, Flange) (1), remove the rear flange (2) nut.
3. Remove the rear output flange from the main shaft. If necessary, use a suitable 2 or 3 jaw puller to remove the output flange.
4. Remove encoder screws and the encoder from the transfer case.
5. Remove the shift shaft snap ring from the transfer case.
6. Remove shift motor bolts and the shift motor from the transfer case.
7. Remove the o-ring from the shift motor.
8. Using a suitable pry tool, remove shift motor seal from the transfer case.
9. Remove the worm shaft snap ring from the transfer case. CAUTION: Carefully unthread (rotate clockwise) the worm shaft to remove it from the transfer case. Failure to follow this caution may result in parts damage.
10. Remove the worm shaft from the transfer case NOTE: Some prying may be necessary to break the seal between the front and rear case. Use care to not damage the sealing surfaces.
11. Remove the bolts retaining the rear housing to the front housing and separate the housings.
12. Remove the output shaft thrust washer.
13. Remove the oil pump assembly.
14. Remove oil tube (1) from the oil pump and remove the o-ring (2).
15. Remove the pick-up magnet from the magnet pocket. NOTE: For ease of installation note the orientation of the worm shaft drive gear inner splines to the shift shaft outer splines.
16. Remove the worm drive gear. NOTE: For ease of installation note the orientation of the clutch cam inner splines to the shift shaft outer splines.
17. Remove the clutch cam.
18. Remove the clutch upper snap ring.
19. Remove the clutch shim.
20. Remove the thrust collar.
21. Remove the upper thrust bearing race.
22. Remove the upper thrust bearing.
23. Remove the upper shift lever.
24. Remove the shift lever balls.
25. Remove the lower shift lever.
26. Remove the lower thrust bearing.
27. Remove the lower thrust bearing race.
28. Remove the clutch apply piston. NOTE: For ease of installation note the assembly orientation of the 4 identical springs.
29. Remove the clutch return springs.
30. Remove the clutch pack.
31. Remove the inner clutch hub.
32. Remove the clutch drum thrust washer (1) and snap ring (2).
33. Remove the outer clutch drum from the mainshaft drive sprocket.
34. Remove the front drive sprocket, mainshaft drive sprocket and drive chain as one.
35. Remove the shift shaft spacer. NOTE: For ease of installation note the orientation of the barrel cam inner splines to the shift shaft outer splines.
36. Remove the barrel cam.
37. Remove the shift shaft.
38. Remove the main shaft from the transfer case.
39. Remove the detent assembly. NOTE: For ease of assembly note the orientation of the shift fork to the shift rail.
40. Remove the range shift rail assembly and range sleeve. Remove the rail, bracket, spring and washers from the shift fork.
41. Remove the retaining snap ring from the front output shaft.
42. Remove the front output shaft from the transfer case.
43. Using a suitable pry tool or a screw mounted in a slide hammer, remove the input gear seal. Remove the input gear snap ring.
44. Remove the input planetary gear assembly from the front housing.
45. Remove the snap-ring holding the input gear into the planetary gear.
46. Remove the lock plate from the input and planetary gear assembly.
47. Remove the thrust washer from the input and planetary gear assembly.
48. Remove the input gear from the planetary gear.
49. Remove the tabbed thrust washer from the planetary gear.