Transfer Case MP 3023

2014 Dodge Durango Limited
2014 TRANSFER CASE MP3023 - Service Information - Durango
2014 TRANSFER CASE
MP3023 - Service Information - Durango
DESCRIPTION
DESCRIPTION
The Select-Trac® II is the MP3023 two-speed, on-demand, active four-wheel drive transfer case that provides
optimum traction for a wide range of conditions, while maximizing driver convenience. When operating in
4WD Auto mode, this sophisticated system anticipates and prevents slip by redirecting torque as necessary.
For added traction capability when traversing steep grades, rough terrain or extremely poor traction surfaces,
the transfer case includes a 4WD Low mode. This second speed gear multiplies engine torque 2.72 times and
locks the clutch pack for maximum traction.
Electric shifting between 4WD AUTO and 4WD Low is effected with a console-mounted switch. A pushpin
button is used to shift to Neutral mode.
The MP3023 transfer case provides the following benefits:
Active, on-demand four-wheel drive requires no driver input.

Instantly anticipates slip and preemptively redirects torque as needed.
Vehicle stability under all conditions because torque is constantly being transferred.
4WD Low operation mode provides an advantage over vehicles equipped with a single-speed all-wheel
drive transfer case.
Electric shifting between 4WD Auto and 4WD Low provides smooth operation and improved NVH
control compared to systems with mechanical linkage.
Enhanced traction and stability provided by the Traction Control and Electronic Stability Program (ESP)
working in tandem with four-wheel-drive.
A robust design and sealing for reliability.
Maintenance-free.
A neutral mode permits flat towing.
OPERATING RANGES
Transfer case operating ranges are:
Operating positions: 4WD Auto - N - 4WD Low.

4WD Auto = Electronically controlled wet clutch for torque biasing.
N = Transfer case neutral for 4-wheel flat recreational towing.
4WD Low = Low range (2.72:1) part time mode.
The 4WD Low range is for off road use only. It is not for use on hard surface roads unless the road surface is
wet, slippery, or covered by ice and snow.
The low range reduction gear system is operative in 4WD Low range only. This range is for extra pulling power
in off road situations. Low range reduction ratio is 2.72:1.
OPERATION
OPERATION
ACTIVE TRANSFER CASE CONTROLS
Controls for the MP3023 transfer case active clutch (torque biasing device) are located in the Drive Train
Control Module (DTCM) and communicated on the Controller Area Network (CAN) C bus. The DTCM
monitors multiple vehicle sensors to anticipate conditions which may result in wheel slip or reduced
performance and preemptively adjusts torque split to front and rear axles as needed. The DTCM also compares
wheel speeds at the front and rear axles to detect wheel slippage. A complete vehicle dynamics model, or
algorithm, calculates slip at each tire for given vehicle-operating conditions. When wheel slip is detected,
pressure applied to the transfer case clutch pack can be increased or decreased to apply increased torque to the
axle with higher traction.
TRANSFER CASE MODES
The transfer case operates in active full-time four-wheel drive (4WD AUTO) unless the driver chooses 4WD
Low, or Neutral.
ELECTRIC SHIFT MECHANISM
The electronically controlled wet clutch pack uses an electric motor to actuate an internal gear train, clutch cam,
and low range barrel cam. The clutch cam actuates the clutch levers that apply normal force to the multi-disc
wet clutch pack. The clutch discs are alternately splined to the front and rear drive shafts. When normal force is
applied to this clutch pack, torque is transferred to equalize speed differences between front and rear axles.
Transfer of torque from one wheel to the other on an axle is accomplished by using Brake Traction Control.
Under the right conditions the vehicle can be driven by just one wheel.
ELECTRONIC STABILITY PROGRAM (ESP)
Standard Electronic Stability Program (ESP) works with the four-wheel drive system to enhance traction and
control through three new features: Hill Descent, Hill Start Assist and Trailer Sway Control.
DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - TRANSFER CASE - MP3023
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
Transfer case difficult to shift or 1) Transfer case electronically 1) Check for Transfer Case DTCs.
will not shift into desired range. controlled shift system Refer to DTC INDEX and
malfunction. depending on vehicle configuration
(FCM, FDCM, or DTCM), perform
the appropriate diagnostic
procedure and verification test.
2) Insufficient or incorrect 2) Drain and refill transfer case with
lubricant. the correct quantity of Mopar®
ATF +4.
3) Internal transfer case 3) Repair or replace components as
components binding, worn, or necessary.
damaged.
Transfer case noisy in all drive 1) Insufficient or incorrect 1) Drain and refill transfer case with
modes. lubricant. the correct quantity of Mopar®
ATF+4.
2) Internal transfer case 2) Repair or replace components as
components binding, worn, or necessary.
damaged.
Transfer case noisy while in, or 1) Transfer case not completely 1) While rolling 2-3 MPH and the
jumps out of, 4LOW. engaged in 4LOW position. transmission in NEUTRAL shift the
transfer case to the 4WD AUTO
position, and then back into the
4LOW position.
2) Range fork, input gear, or 2) Repair or replace components as
range sleeve damaged, inserts necessary.
worn, or fork is binding on the
shift rail.
3) Low range gear worn or 3) Repair or replace components as
damaged. necessary.
Lubricant leaking from transfer 1) Transfer case overfilled. 1) Drain lubricant to the correct
case seals or vent. level.
2) Transfer case vent closed or 2) Clean or replace vent as
restricted. necessary.
3) Transfer case seals damaged 3) Replace suspect seals. Inspect
or installed incorrectly. and replace, if necessary, the seal
slinger on the output flange
associated with the damaged seal.
SPECIFICATIONS
SPECIFICATIONS
MP3023 FLUID
TYPE QUANTITY
ATF+4 1.90L (4.01 Pints)
Fill to bottom edge of the fill plug hole.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION N.m Ft. Lbs. In. Lbs.
Bolt, Crossmember 55 41 -
Plug, Clutch Lever Rail (Detent) 20-34 15-25 -
Plugs, Drain/Fill 20-34 15-25 -
Bolts, Case Half 27 20 -
Nut, Companion Flange 122-176 90-130 -
Bolts, T-case mount 41-49 30-36 -
Bolts, Shift Motor 13 9 -
Screws, Encoder 6-8 - 48-71
Bolts, Damper (if equipped) 35 26 -
REMOVAL
REMOVAL
Fig. 1: Fill Plug & Drain Plug

Courtesy of CHRYSLER GROUP, LLC
1. Shift transfer case into NEUTRAL.

2. Raise vehicle.
3. Remove transfer case fill plug (1) and drain plug (2) to drain transfer case lubricant.
Fig. 2: Transfer Case, Transmission & Bolts

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 and SHAFT, DRIVE, REAR, REMOVAL .
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.
DISASSEMBLY
DISASSEMBLY
Fig. 3: Exploded View Of Transfer Case Components

1 - HOUDINI RETAINING RING

2 - INPUT BALL BEARING
3 - RETAINING RING
4 - CARRIER LOCK PLATE
5 - FRONT CARRIER THRUST WASHER
6 - INPUT GEAR ASSEMBLY
7 - CARRIER THRUST SHIM
8 - PLANETARY CARRIER ASSEMBLY
9 - RANGE SLEEVE
10 - MAINSHAFT ASSEMBLY
11 - OIL PUMP ASSEMBLY
12 - REAR THRUST WASHER
13 - REAR WEAR SLEEVE
14 - REAR OUTPUT FLANGE
15 - O-RING SEAL
16 - FLANGE NUT
17 - SCREW
18 - SHIFT MOTOR
19 - WORM SHAFT OIL SEAL
20 - RETAINING RING
21 - RETAINING RING
22 - BALL BEARING
23 - WORM SHAFT
24 - SHIFT RAIL
25 - RANGE FORK PAD
26 - RANGE FORK
27 - SLEEVE WASHER
28 - SPRING
29 - BRACKET ASSEMBLY
30 - RETAINING RING
31 - BARREL CAM
32 - SHIFT SHAFT ASSEMBLY
33 - BUSHING
34 - CLUTCH CAM
35 - GEAR
36 - COUPLING
37 - RETAINING RING
38 - BEARING
39 - REAR CASE HALF ASSEMBLY
40 - BOLT
41 - SCREW
42 - RADIAL SEAL RING
43 - SENSOR
44 - SCREW
45 - RETAINING RING
46 - SCREW
47 - IDENTIFICATION TAG
48 - FILL/DRAIN PLUG
49 - REAR BEARING
50 - SHIFT SHAFT BEARING RETAINING RING
51 - SHIFT SHAFT BEARING
52 - TUBE & SCREEN ASSEMBLY
53 - O-RING SEAL
54 - MAGNET
55 - SCREW
56 - SPRING
57 - DETENT POPPET
58 - CHAIN
59 - SPROCKET
60 - RETAINING RING
61 - FRONT BEARING
62 - FRONT CASE HALF ASSEMBLY

63 - DOWEL BUSHING
65 - FRONT WEAR SLEEVE
66 - FRONT OUTPUT FLANGE
67 - RETAINING RING
68 - INPUT SEAL
69 - VENT
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.
1. Place the transfer case in a shallow pan and remove the fill and drain plugs to drain the remainder of the
fluid.
Fig. 4: Holder & Rear Flange

2. Using Holder (special tool #C-3281, Holder, Flange) (1), remove the rear flange (2) nut.
Fig. 5: Rear Output Flange

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.
Fig. 6: Encoder & Transfer Case

4. Remove encoder screws and the encoder from the transfer case.
Fig. 7: Shift Shaft Snap Ring

5. Remove the shift shaft snap ring from the transfer case.
Fig. 8: Shift Motor

6. Remove shift motor bolts and the shift motor from the transfer case.
Fig. 9: Shift Motor O-Ring

7. Remove the o-ring from the shift motor.
Fig. 10: Shift Motor Seal

8. Using a suitable pry tool, remove shift motor seal from the transfer case.
Fig. 11: Worm Shaft Snap Ring

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.
Fig. 12: Worm Shaft

10. Remove the worm shaft from the transfer case

Fig. 13: 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.
Fig. 14: Output Shaft Thrust Washer

12. Remove the output shaft thrust washer.

Fig. 15: Oil Pump Assembly

13. Remove the oil pump assembly.
Fig. 16: Oil Tube O-Ring

14. Remove oil tube (1) from the oil pump and remove the o-ring (2).
Fig. 17: Pick-Up Magnet

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.
Fig. 18: Worm Shaft Drive Gear

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.
Fig. 19: Clutch Cam

17. Remove the clutch cam.
Fig. 20: Clutch Upper Snap Ring

18. Remove the clutch upper snap ring.
Fig. 21: Clutch Shim

19. Remove the clutch shim.
Fig. 22: Thrust Collar

20. Remove the thrust collar.

Fig. 23: Upper Bearing Race

21. Remove the upper thrust bearing race.
Fig. 24: Upper Bearing

22. Remove the upper thrust bearing.

Fig. 25: Upper Shift Lever

23. Remove the upper shift lever.
Fig. 26: Shift Lever Balls

24. Remove the shift lever balls.

Fig. 27: Lower Shift Lever

25. Remove the lower shift lever.
Fig. 28: Lower Bearing

26. Remove the lower thrust bearing.

Fig. 29: Lower Race

27. Remove the lower thrust bearing race.
Fig. 30: Clutch Apply Piston

28. Remove the clutch apply piston.

NOTE: For ease of installation note the assembly orientation of the 4 identical
springs.
Fig. 31: Clutch Return Springs

29. Remove the clutch return springs.
Fig. 32: Clutch Pack

30. Remove the clutch pack.

Fig. 33: Clutch Inner Hub

31. Remove the inner clutch hub.
Fig. 34: Clutch Hub Snap Ring & Thrust Washer

32. Remove the clutch drum thrust washer (1) and snap ring (2).
Fig. 35: Clutch Drum

33. Remove the outer clutch drum from the mainshaft drive sprocket.
Fig. 36: Front Drive Sprocket, Mainshaft Drive Sprocket & Drive Chain
34. Remove the front drive sprocket, mainshaft drive sprocket and drive chain as one.
Fig. 37: Shift Shaft Spacer

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.
Fig. 38: Barrel Cam

36. Remove the barrel cam.
Fig. 39: Shift Shaft

37. Remove the shift shaft.
Fig. 40: Main Shaft

38. Remove the main shaft from the transfer case.

Fig. 41: Detent Assembly

39. Remove the detent assembly.
Fig. 42: Range Shift Rail Assembly, Range Sleeve Rail, Bracket, Spring & Washers
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.
Fig. 43: Front Output Shaft Snap Ring

41. Remove the retaining snap ring from the front output shaft.
Fig. 44: Front Output Shaft

42. Remove the front output shaft from the transfer case.
Fig. 45: Input Gear Snap Ring

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.
Fig. 46: Input Planetary Gear Assembly

44. Remove the input planetary gear assembly from the front housing.
Fig. 47: Low Gear Snap Ring

45. Remove the snap-ring holding the input gear into the planetary gear.
Fig. 48: Input Gear Retainer Removal

46. Remove the lock plate from the input and planetary gear assembly.
Fig. 49: Input Gear Lock Plate

47. Remove the thrust washer from the input and planetary gear assembly.
Fig. 50: Input Gear

48. Remove the input gear from the planetary gear.
Fig. 51: Low Gear Tabbed Thrust Washer

49. Remove the tabbed thrust washer from the planetary gear.
CLEANING
CLEANING
Clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases
and retainers with a scraper and 3M™ all purpose cleaner. Use compressed air to remove solvent residue from
oil feed passages in the case halves, retainers, gears, and shafts.
INSPECTION
INSPECTION
Inspect the case for cracks, porous spots, worn bores, or damaged threads. Damaged threads can be repaired
with Helicoil® thread inserts. However, the case will have to be replaced if it exhibits any type of damage or
wear.
ASSEMBLY
ASSEMBLY
Fig. 52: Exploded View Of Transfer Case Components

1 - HOUDINI RETAINING RING

2 - INPUT BALL BEARING
3 - RETAINING RING
4 - CARRIER LOCK PLATE
5 - FRONT CARRIER THRUST WASHER
6 - INPUT GEAR ASSEMBLY
7 - CARRIER THRUST SHIM
8 - PLANETARY CARRIER ASSEMBLY
9 - RANGE SLEEVE
10 - MAINSHAFT ASSEMBLY
11 - OIL PUMP ASSEMBLY
12 - REAR THRUST WASHER
13 - REAR WEAR SLEEVE
14 - REAR OUTPUT FLANGE
15 - O-RING SEAL
16 - FLANGE NUT
17 - SCREW
18 - SHIFT MOTOR
19 - WORM SHAFT OIL SEAL
20 - RETAINING RING
21 - RETAINING RING
22 - BALL BEARING
23 - WORM SHAFT
24 - SHIFT RAIL
25 - RANGE FORK PAD
26 - RANGE FORK
27 - SLEEVE WASHER
28 - SPRING
29 - BRACKET ASSEMBLY
30 - RETAINING RING
31 - BARREL CAM
32 - SHIFT SHAFT ASSEMBLY
33 - BUSHING
34 - CLUTCH CAM
35 - GEAR
36 - COUPLING
37 - RETAINING RING
38 - BEARING
39 - REAR CASE HALF ASSEMBLY
40 - BOLT
41 - SCREW
43 - SENSOR
44 - SCREW
45 - RETAINING RING
46 - SCREW
47 - IDENTIFICATION TAG
48 - FILL/DRAIN PLUG
49 - REAR BEARING
50 - SHIFT SHAFT BEARING RETAINING RING
51 - SHIFT SHAFT BEARING
52 - TUBE & SCREEN ASSEMBLY
53 - O-RING SEAL
54 - MAGNET
55 - SCREW
56 - SPRING
57 - DETENT POPPET
58 - CHAIN
59 - SPROCKET
60 - RETAINING RING
61 - FRONT BEARING
62 - FRONT CASE HALF ASSEMBLY

63 - DOWEL BUSHING
65 - FRONT WEAR SLEEVE
66 - FRONT OUTPUT FLANGE
67 - RETAINING RING
68 - INPUT SEAL
69 - VENT

Scan Tool.
NOTE: Lubricate all seals with MOPAR® ATF+4 prior to installation.
CAUTION: The bearing bores in various transfer case components contain oil feed
holes. Be certain the holes are not blocked. Failure to follow this caution
may result in transfer case damage.
Fig. 53: Input Shaft Bearing & Front Case

1. While holding the retaining ring tabs apart with suitable snap-ring pliers, remove the input shaft bearing
(1) from the front case (2).
2. Transfer the retaining ring to the new housing, if necessary, and install the bearing into the front case.
Fig. 54: Transfer Case, Installer & Driver Handle

3. Using a suitable pry tool or a screw mounted in a slide hammer, remove the front output shaft seal.
4. Using Installer (special tool #6061, Installer, Cup) inverted, and Handle (special tool #C-4171, Driver
Handle, Universal), remove front output shaft bearing.
5. Start front output shaft bearing in case. Then seat bearing with Handle (special tool #C-4171, Driver
Handle, Universal) (3) and Installer (special tool #C-4210, Installer, Seal) (2).
6. Install the front output shaft seal using Installer (special tool #6560, Installer, Bearing Cup).
Fig. 55: Installing Rear Output Shaft Seal

7. Using a suitable pry tool or a screw mounted in a slide hammer, remove the rear output shaft seal.
8. Remove the rear output shaft bearing from the rear case using Installer (special tool #L-4408, Installer,
Bearing) (2) inverted and Handle (special tool #C-4171, Driver Handle, Universal) (1).
9. Install the rear output shaft bearing into the rear case using Remover/Installer (special tool #6061,
Installer, Cup) inverted and Handle (special tool #C-4171, Driver Handle, Universal).
Fig. 56: Shift Shaft Bearing Snap Ring

10. Remove shift shaft bearing snap ring.
Fig. 57: Removing Shift Shaft Bearing

11. Remove shift shaft bearing using Handle (special tool #C-4171, Driver Handle, Universal) (1) and
Installer / Remove (special tool #5066, Installer, Bushing) (2).
Fig. 58: Shift Shaft Bearing Installation

12. Install shift shaft bearing using Handle (special tool #C-4171, Driver Handle, Universal) and Installer /
Remover (special tool #5066, Installer, Bushing) inverted.
Fig. 59: Shift Shaft Bearing Snap Ring

13. Install shift shaft bearing snap ring.
Fig. 60: Removing Front Output Shaft Rear Bearing

14. Remove front output shaft rear bearing from housing using Puller (special tool #7794-A, Remover, Seal)
(1) and Slide Hammer (special tool #C-637, Slide Hammer, Universal) (2).
Fig. 61: Installing Front Output Shaft Rear Bearing

15. Install front output shaft rear bearing in housing using Installer (special tool #6061, Installer, Cup) (2)
inverted and Handle (special tool #C-4171, Driver Handle, Universal) (2).
Fig. 62: Front Output Shaft

16. Install the front output shaft flange (2) into the front housing (1).
Fig. 63: Front Output Shaft Snap Ring

17. Install the front output shaft snap ring.

Fig. 64: Low Gear Tabbed Thrust Washer

18. Install the bottom thrust tabbed washer into the planetary gear.
Fig. 65: Input Gear

19. Install the input gear into the planetary gear.
Fig. 66: Input Gear Lock Plate

20. Install the thrust washer onto the input planetary gear assembly.
Fig. 67: Input Gear Retainer Removal

21. Install the lock plate onto the input planetary gear assembly.
Fig. 68: Low Gear Snap Ring

22. Install the snap ring into the input planetary gear assembly.
Fig. 69: Input Planetary Gear Assembly

23. Install the input planetary gear assembly into the front housing.
Fig. 70: Input Gear Snap Ring

24. Install the input gear snap ring.
Fig. 71: Installing Input Shaft Seal

25. Using Installer (special tool #9672, Installer, Seal) (2) and Handle (special tool #C-4171, Driver Handle,
Universal) (1), install a new input shaft seal.
Fig. 72: Range Shift Rail Assembly, Range Sleeve Rail, Bracket, Spring & Washers
26. Install the spring washers onto each side of the spring and install the spring assembly into the shift fork.
27. Install the shift bracket over the spring washers and onto the shift fork.
28. Install the range sleeve into the shift fork.
29. Install the range shift assembly and range sleeve.
Fig. 73: Detent Assembly

30. Install the detent assembly.

Fig. 74: Main Shaft

31. Install the mainshaft into the transfer case.
Fig. 75: Shift Shaft

32. Install the shift shaft.
NOTE: Before installing the barrel cam, note the orientation of the inner barrel
cam splines to the outer splines on the shift shaft.
Fig. 76: Barrel Cam

33. Install the barrel cam.
Fig. 77: Shift Shaft Spacer

34. Install the shift shaft spacer.

Fig. 78: Front Drive Sprocket, Mainshaft Drive Sprocket & Drive Chain
NOTE: There is a blue link on one side of the chain. This blue link MUST be
installed facing upward.
35. Install the front drive sprocket, mainshaft drive sprocket and drive chain as one.

36. Install the outer clutch drum onto the mainshaft drive sprocket.

37. Install the clutch drum snap ring (2) and thrust washer (1).

38. Install the inner clutch hub.


39. Starting with a friction disc and ending with a friction disc, install the clutch pack.

40. Install the clutch return springs.


41. Install the clutch apply piston with the lettering up and the stepped face down.
Fig. 85: Lower Race

42. Install the lower bearing race with the race fitting into the grove in the reaction plate.

43. Install the lower bearing.

44. Install the lower shift lever.


45. Install the shift lever balls into their pockets.

46. Install the upper shift lever.


47. Install the upper thrust bearing.

48. Install the upper bearing race.


49. Install the thrust collar.

50. Install the clutch shim.


51. Install clutch upper snap ring.
NOTE: The clutch cam has the word "FRONT" stamped into. This identifies the
orientation of the clutch cam to the front of the transfer case. Before
installing the clutch cam, note the orientation of the clutch cam inner
splines to the outer splines on the shift shaft. Install it such that the roller
falls into low point of clutch cam.
Fig. 95: Clutch Cam

52. Install the clutch cam.
NOTE: Before installing the worm drive gear, note the orientation of the worm
drive gear inner splines to the outer splines on the shift shaft.
Fig. 96: Worm Shaft Drive Gear

53. Install the worm drive gear.

Fig. 97: Pick-Up Magnet

54. Install the magnet into the magnet pocket.
Fig. 98: Oil Tube O-Ring

1 - OIL TUBE
2 - O-RING SEAL
55. Install a new o-ring (2) onto the oil pump tube (1).
Fig. 99: Oil Pump Assembly

56. Lubricate the oil tube o-ring with MOPAR® ATF+4 and install the tube into the oil pump.
57. Install the oil pump assembly.
Fig. 100: Output Shaft Thrust Washer

58. install the output shaft thrust washer.

NOTE: Do not use excessive amount of sealer as excess could be displaced into
the oil pump. Keep sealer bead width to maximum of 3 mm (1/8 inch).
59. Apply bead of Mopar® Gasket Maker, or equivalent, to one of the mating surfaces of the front or rear
housing.
60. Install the rear housing onto the front housing. Install the housing bolts. Tighten housing bolts in a
crisscross pattern to 27 N.m (20 ft. lbs.).
CAUTION: Carefully align and thread (rotate counterclockwise) the worm shaft
to install it into the transfer case. Failure to follow this caution may
result in parts damage.
Fig. 102: Worm Shaft

61. Install the worm shaft into the transfer case.
NOTE: It may be necessary to apply slight inward pressure on the worm shaft to
seat the snap ring.
Fig. 103: Worm Shaft Snap Ring

62. Install the worm shaft snap ring.
Fig. 104: Shift Motor Seal

63. Using a suitable installer, install the shift motor seal.


64. Install a new o-ring onto the shift motor.
Fig. 106: Shift Motor

NOTE: Note the orientation of the shift motor shaft to the worm gear shaft.
65. Install the shift motor onto the transfer case. Install the shift motor bolts. Tighten the shift motor bolts to
13 N.m (9 ft. lbs.).
Fig. 107: Shift Shaft Snap Ring

NOTE: It may be necessary to pull out on the shift shaft to properly seat the shift
shaft snap ring.
66. Install the shift shaft snap ring.
Fig. 108: Arrow & Alignment Mark

67. 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.

68. Install the encoder onto the rear transfer case housing. Install the encoder screws. Tighten the screws to 5-
8 N.m (44-71 in. lbs.).
Fig. 110: Rear Cover Seal Installation

69. Using a suitable pry tool or a screw mounted in a slide hammer, remove the rear cover seal.
70. Using Installer (special tool #C-4210, Installer, Seal) (2) and Handle (special tool #C-4171, Driver
Handle, Universal) (1), install the rear cover seal.

71. Install the companion flange onto the mainshaft.

72. Using Holder (special tool #C-3281, Holder, Flange) (1), install the rear output flange (2) nut. Tighten the
nut to 122-176 N.m (90-130 ft. lbs.).
INSTALLATION
INSTALLATION
Fig. 113: Transfer Case, Transmission & Bolts

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 and SHAFT, DRIVE, REAR, INSTALLATION .
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 . 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.
SPECIAL TOOLS
SPECIAL TOOLS
5066 - Installer, Bushing

(Originally Shipped In Kit Number(s)
9975.)
6061 - Installer, Cup

6303, 6822.)
6560 - Installer, Bearing Cup

6671, 9698.)
7794-A - Remover, Seal

6645.)
9672 - Installer, Seal

9696, 9697, 9698.)
C-3281 - Holder, Flange

9202, 9202A-CAN, 9202CC, 9299,
9299CC, 9299CC, 9300A-CAN.)
C-4171 - Driver Handle, Universal

9202, 9202A-CAN, 9202CC, 9299,
9299CC, 9299CC, 9300A-CAN.)
C-4210 - Installer, Seal

9975.)
C-637 - Slide Hammer, Universal

9202.)
L-4408 - Installer, Bearing

CLUTCH
DISASSEMBLY
DISASSEMBLY
Fig. 115: Exploded View Of Clutch Components

1 - MAINSHAFT
2 - DRIVE SPROCKET
3 - CLUTCH HOUSING
4 - CLUTCH HOUSING RETAINING RING
5 - SPROCKET SPACER T-WASHER
6 - CLUTCH HUB
7 - FRICTION PLATE
8 - STEEL REACTION PLATE
9 - CLUTCH SPRING
10 - CLUTCH PISTON
11 - THRUST WASHER
12 - THRUST BEARING
13 - BALL RAMP A LEVER
14 - BALL
15 - LEVER B ASSEMBLY
16 - THRUST BEARING
17 - THRUST WASHER
18 - THRUST COLLAR
19 - CLUTCH SHIM
20 - RETAINING RING

Scan Tool.

1. Remove the clutch upper snap ring.

2. Remove the clutch shim.

3. Remove the thrust collar.


4. Remove the upper thrust bearing race.

5. Remove the upper thrust bearing.


6. Remove the upper shift lever.

7. Remove the shift lever balls.


8. Remove the lower shift lever.

9. Remove the lower thrust bearing.

Fig. 125: Lower Race

10. Remove the lower bearing race.

11. Remove the clutch apply piston.

NOTE: For ease of installation note the assembly orientation of the 4 identical
springs.

12. Remove the clutch return springs.
NOTE: For ease of installation note the assembly configuration of the clutch
plates and friction discs.

13. Remove the clutch pack.

14. Remove the inner clutch hub.

15. Remove the clutch hub thrust washer (1) and snap ring (2).

16. Remove the outer clutch drum from the main shaft and drive sprocket.
ASSEMBLY
ASSEMBLY
Fig. 132: Exploded View Of Clutch Components

1 - MAINSHAFT
2 - DRIVE SPROCKET
3 - CLUTCH HOUSING
4 - CLUTCH HOUSING RETAINING RING
5 - SPROCKET SPACER T-WASHER
6 - CLUTCH HUB
7 - FRICTION PLATE
8 - STEEL REACTION PLATE
9 - CLUTCH SPRING
10 - CLUTCH PISTON
11 - THRUST WASHER
12 - THRUST BEARING
13 - BALL RAMP A LEVER
14 - BALL
15 - LEVER B ASSEMBLY
16 - THRUST BEARING
17 - THRUST WASHER
18 - THRUST COLLAR
19 - CLUTCH SHIM
20 - RETAINING RING

Scan Tool.

1. Install the outer clutch drum onto the main shaft and drive sprocket.

2. Install the clutch hub snap ring (2) and thrust washer (1).

3. Install the inner clutch hub.

4. Starting with friction disc and ending with a friction disc, install the clutch pack.
NOTE: The four identical springs must be installed in the orientation shown in
illustration.

5. Install the clutch return springs.

6. Install the clutch apply piston with the lettering up and the stepped face down.
Fig. 139: Lower Race

7. Install the lower thrust bearing race.

8. Install the lower thrust bearing.


9. Install the lower shift lever.

10. Install the shift lever balls into their pockets.


11. Install the upper shift lever.

12. Install the upper thrust bearing.


13. Install the upper thrust bearing race.

14. Install the thrust collar.


15. Install the clutch shim.

16. Install the clutch upper snap ring.
FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID DRAIN/REFILL
The fill and drain plugs are both in the rear case.

1. Raise vehicle. Ensure that the vehicle is level on the hoist.
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).
2. Position drain pan under transfer case.

3. Remove fill plug (1) and drain plug (2) and drain lubricant completely.
4. Install drain plug (2) and tighten plug to 27 N.m (20 ft. lbs.).
5. Fill transfer case to bottom edge of fill plug opening with MOPAR® ATF+4
6. Install and tighten fill plug (1) and tighten plug to 27 N.m (20 ft. lbs.).
7. Lower vehicle.
MOTOR, SHIFT
DESCRIPTION
DESCRIPTION
Fig. 150: Encoder & Shift Motor

The shift motor (3) is an electromechanical device consisting of a DC permanent magnet motor and a position
holding brake. The shift motors' overall function is to move and lock a gear that moves the range fork and
clutch lever found in the transfer case. This allows the transfer case to be shifted electrically to multiple
operating positions (4WD AUTO and 4WD LOW. The operating current of the shift motor under stall
conditions is 30 amps maximum at 72° F with 13.5 volts, at the motor leads.
OPERATION
OPERATION

Shifting in the transfer case occurs when a Pulse Width Modulated (PWM) voltage is supplied to the shift motor
(3) by the Drive Train Control Module (DTCM). A linear analog position sensor (Encoder) (2) located on the
rear transfer case housing, provides the DTCM with the motors' angular, rotational position. With this
information, the DTCM continuously knows the motors' position, and therefore allows it to accurately control
the motors' operation, including voltage polarity which is used to control motor direction.
The electronically controlled wet clutch pack uses an electric motor to actuate an internal gear train, clutch cam,
and low range barrel cam. The clutch cam actuates the clutch levers that apply normal force to the multi-disc
wet clutch pack. The clutch disks are alternately splined to the front and rear outputs. When normal force is
applied to this clutch pack, torque is transferred to equalize speed differences between front and rear axles.
REMOVAL
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.
INSTALLATION
INSTALLATION

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.
SEAL, INPUT SHAFT, MP3023

REMOVAL
REMOVAL
1. Remove the transfer case from the vehicle. Refer to REMOVAL.

2. Remove the front input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
INSTALLATION
INSTALLATION
Fig. 155: Installing Input Shaft Seal

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.
3. Check the transfer case fluid. Correct as necessary. Refer to STANDARD PROCEDURE .
SEAL, OUTPUT SHAFT, FRONT

REMOVAL
REMOVAL
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.
SEAL, OUTPUT SHAFT, REAR

REMOVAL
REMOVAL

1. Remove the rear propeller shaft. Refer to SHAFT, DRIVE, REAR, REMOVAL .
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.
INSTALLATION
INSTALLATION
Fig. 159: Installing Rear Output Shaft Seal

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, REAR, INSTALLATION .
5. Check the transfer case fluid level. Refer to STANDARD PROCEDURE . Correct as necessary.
SENSOR, MODE
DESCRIPTION
DESCRIPTION

The transfer case Encoder (2) provides the Drive Train Control Module (DTCM) feedback about the position of
the transfer case. The sensor consists of a linear analog position sensor that converts the motor output shaft
position into a DC signal. The sensor may rotate a full 360 degrees. The DTCM must supply 5VDC (+/- 0.5v)
to the sensor whenever the DTCM is not in sleep mode and monitors the shift motor position. The sensor
position is monitored when the ignition is in the RUN position and for 10 seconds after the ignition is shifted to
the OFF position. The sensor is mechanically linked to the shaft of the cam which allows the transfer case to
shift. The mode sensor will draw less than 20 mA of current during operation.
OPERATION
OPERATION
During normal vehicle operation, the DTCM monitors the mode sensor outputs at least every 2 milliseconds
when the shift motor is stationary or active. The mode sensor position will be considered invalid by the DTCM
if the voltage is greater than 4.75 V or if it is less than 0.25 V.
NOTE: All the parameter voltages referred to in the following information are calibrated
items in the controller software and are subject to change.
The DTCM shall consider Transfer Case position based on the MODE SENSOR VOLTAGES table listed
below:
MODE SENSOR VOLTAGES

TRANSFER CASE POSITION Voltage
4WD LOW 0.25 - 0.80
NEUTRAL 1.10 - 1.25
4WD AUTO (ACTIVE) 2.00 - 4.75
REMOVAL
REMOVAL

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.
INSTALLATION
INSTALLATION
Fig. 164: Arrow & Alignment Mark

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.
SWITCH, TRANSFER CASE

DESCRIPTION
DESCRIPTION
Fig. 166: Console-Mounted Switch

Electric shifting between AWD Auto and Low is accomplished with a console-mounted switch (1). A push
button is used to shift to Neutral mode.
All Wheel Drive Auto.

Low Range.
Control Knob.
Neutral button.

Transfer Case MP 3023

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Transfer Case MP 3023

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2014 Dodge Durango Limited

2014 TRANSFER CASE MP3023 - Service Information - Durango

2014 TRANSFER CASE

MP3023 - Service Information - Durango

The MP3023 transfer case provides the following benefits:

Active, on-demand four-wheel drive requires no driver input.

Transfer case operating ranges are:

Operating positions: 4WD Auto - N - 4WD Low.

wet, slippery, or covered by ice and snow.

ACTIVE TRANSFER CASE CONTROLS

TRANSFER CASE MODES

ELECTRIC SHIFT MECHANISM

ELECTRONIC STABILITY PROGRAM (ESP)

DIAGNOSIS AND TESTING

Fig. 1: Fill Plug & Drain Plug

1. Shift transfer case into NEUTRAL.

Fig. 2: Transfer Case, Transmission & Bolts

4. Support transmission (3) with jack stand.

CAUTION: Do not allow propeller shafts to hang at attached end. Damage to

Fig. 3: Exploded View Of Transfer Case Components

1 - HOUDINI RETAINING RING

62 - FRONT CASE HALF ASSEMBLY

NOTE: If the transfer case assembly is being reconditioned (clutch/seal replacement)

Fig. 4: Holder & Rear Flange

Fig. 5: Rear Output Flange

Fig. 6: Encoder & Transfer Case

Fig. 7: Shift Shaft Snap Ring

Fig. 8: Shift Motor

Fig. 9: Shift Motor O-Ring

7. Remove the o-ring from the shift motor.

Fig. 10: Shift Motor Seal

Fig. 11: Worm Shaft Snap Ring

CAUTION: Carefully unthread (rotate clockwise) the worm shaft to remove it

Fig. 12: Worm Shaft

10. Remove the worm shaft from the transfer case

Fig. 13: Transfer Case

Fig. 14: Output Shaft Thrust Washer

12. Remove the output shaft thrust washer.

Fig. 15: Oil Pump Assembly

13. Remove the oil pump assembly.

Fig. 16: Oil Tube O-Ring

Fig. 17: Pick-Up Magnet

15. Remove the pick-up magnet from the magnet pocket.

Fig. 18: Worm Shaft Drive Gear

16. Remove the worm drive gear.

Fig. 19: Clutch Cam

17. Remove the clutch cam.

Fig. 20: Clutch Upper Snap Ring

18. Remove the clutch upper snap ring.

Fig. 21: Clutch Shim

19. Remove the clutch shim.

Fig. 22: Thrust Collar

20. Remove the thrust collar.

Fig. 23: Upper Bearing Race

21. Remove the upper thrust bearing race.

Fig. 24: Upper Bearing

22. Remove the upper thrust bearing.

Fig. 25: Upper Shift Lever

23. Remove the upper shift lever.

Fig. 26: Shift Lever Balls

24. Remove the shift lever balls.

Fig. 27: Lower Shift Lever

25. Remove the lower shift lever.