Manual de serviço - Grand Cherokee - SM_70_221116

DESCRIPTION > DESCRIPTION
The MP3010 is a single speed transfer case which provides convenient full-time all-wheel-drive. No
driver interaction is required. This transfer case divides engine torque almost evenly, with 47 percent of
engine torque to the front axle and 53 percent of engine torque to the rear axle, resulting in a vehicle
with good traction and stability
OPERATION > OPERATION
Normal All-Wheel Drive allows front and rear wheels to rotate at different speeds on all road surfaces.
The "SVC 4WD" warning light monitors the electric shift 4WD system. If this light remains on after engine
start up or illuminates during driving, it means that the 4WD system is not functioning properly and that
service is required.
Proper operation of all-wheel drive vehicles depends on tires of equal size, type and circumference on
each wheel. Any difference in tire size can cause damage to the transfer case.
The DTCM (Drive Train Control Module) is an electronic module that controls the shifting of the 4WD
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"Active on Demand" MP3010 single speed transfer case.
The MP3010 is a single speed transfer case which provides convenient full-time all-wheel-drive. No
driver interaction is required. The DTCM module governs the torque split between the front and rear axle.
Driving down a straight line on a dry surface the transfer case sends 47 percent of the torque to the
front axle and 53 percent of torque to the rear axle. This four-wheel drive (4WD) system allows front and
rear wheels to rotate at different speeds when required by the road condition or road surface.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - TRANSFER CASE - MP3010
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
Transfer case noisy in all drive 1) Insufficient or incorrect 1) Drain and refill transfer case
modes. lubricant. with the correct quantity of Mopar®
ATF +4, Automatic Transmission
Fluid.
2) Internal transfer case 2) Repair or replace components

components binding, worn, or as necessary.
damaged.
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 seal.
or installed incorrectly.
SPECIFICATIONS > SPECIFICATIONS

MP3010 FLUID
TYPE QUANTITY
ATF+4 1.35L (2.85 Pints)(1)
(1) Fill to bottom edge of the fill plug hole.
TORQUE SPECIFICATIONS
DESCRIPTION N.m Ft. Lbs. In. Lbs. COMMENTS
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Bolts, Crossmember to Frame 54 40 -
Bolts, Clevis Bracket to

54 40 -
Transmission
Nuts, Crossmember to
54 40 -
Transmission Mount
Plug, Clutch Lever Rail (Detent) 27 20 -
Plugs, Drain/Fill 27 20 -
Bolts, Case Half 27 20 -
Bolts, Rear Cover 27 20 -
Nuts, T-case mount stud 35 26 -
Bolts, Shift Motor 13 9 -
Screws, Encoder 6.5 - 58
REMOVAL > REMOVAL
WARNING:
Always secure your vehicle by fully applying the parking brake, before activating the Manual
Park Release. Activating the Manual Park Release will allow your vehicle to roll away if it is
not secured by the parking brake or by proper connection to a tow vehicle. Activating the
Manual Park Release on an unsecured vehicle could lead to serious injury or death for
those in or around the vehicle.
1. Engage the Manual Park Release (MPR) lever.
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).
Fig 1: Fill Plug & Drain Plug
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Courtesy of CHRYSLER GROUP, LLC
3. Remove transfer case fill plug (1) and drain plug (2) to drain transfer case lubricant.
Fig 2: Transfer Case, Transmission & Bolts
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4. Support transmission (3) with jack stand.
5. Remove skid plate, if equipped.
CAUTION:
Do not allow propeller shafts to hang at attached end. Damage to joint can result.
6. 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 .
NOTE:
It may be necessary to remove the heat shield to access the t-case connectors.
7. Disconnect the transfer case shift motor and mode sensor electrical connector.
8. Disconnect transfer case vent hose.
9. Support transfer case (1) with transmission jack.
10. Secure transfer case to jack with chains.
11. Remove bolts (3) attaching transfer case to transmission (2).
12. Pull transfer case and jack rearward to disengage transfer case.
13. Remove transfer case from under vehicle.
DISASSEMBLY > DISASSEMBLY
NOTE:
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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.
Fig 1: Exploded View Of MP3010 Transfer Case

1 - BOOT CLAMP
2 - BOOT
3 - BOOT CLAMP
4 - OIL SLINGER
5 - FRONT OUTPUT SEAL
6 - FRONT CASE
7 - FRONT OUTPUT / FRONT INPUT BEARING
8 - DOWEL
9 - MAGNET
10 - FRONT OUTPUT SHAFT
11 - GEMINI CHAIN
12 - OIL PUMP PICK-UP TUBE
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13 - OIL PUMP TUBE O-RING
14 - DRIVE SPROCKET
15 - RETAINING RING
16 - REAR CASE BEARING
17 - REAR OUTPUT BEARING
18 - REAR CASE
19 - CASE BOLTS
20 - WORM SHAFT NEEDLE BEARING
21 - WORM SHAFT
22 - WORM SHAFT BEARING
23 - WORM SHAFT BEARING RETAINING RING
24 - E-CLIP
25 - WORM SHAFT SEAL
26 - SHIFT MOTOR
27 - SHIFT MOTOR BOLTS
28 - ENCODER BOLTS
29 - ENCODER
30 - REAR OUTPUT SHAFT SEAL
31 - BUSHING
32 - ENCODER SEAL
33 - ID TAG
34 - RETAINING RING
35 - BREATHER TUBE
36 - FILL / DRAIN PLUG
37 - CASE BOLTS
38 - OIL PUMP
39 - RETAINING RING
40 - SHIM
41 - THRUST COLLAR
42 - THRUST WASHER
43 - NEEDLE BEARING
44 - SHIFT BEARING ACTUATOR
45 - OUTER BEARING RACE
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46 - NEEDLE BEARING
47 - UPPER LEVER
48 - LEVER BALLS
49 - LOWER LEVER
50 - NEEDLE BEARING
51 - THRUST WASHER
52 - CLUTCH PISTON
53 - CLUTCH SPRING
54 - BEARING
55 - RETAINING RING
56 - WORM DRIVE GEAR
57 - REACTION PLATE
58 - FRICTION PLATE
59 - CLUTCH CAM
60 - SPACER
61 - CLUTCH HUB
62 - RETAINING RING
63 - POSITION SENSOR COUPLER
64 - RETAINING RING
65 - BUSHING
66 - CLUTCH DRUM
67 - SHIFT SHAFT
68 - BUSHING
69 - SHIFT RAIL
70 - MAIN SHAFT
71 - PLUG
72 - HUB SPROCKET
73 - BUSHING
74 - DRIVE SPROCKET
75 - RETAINING RING
76 - THRUST WASHER
77 - RETAINING RING
78 - BAR CODE LABEL
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79 - INPUT SHAFT SEAL
80 - BOLT STUDS
1. Place the transfer case in a shallow pan and remove the fill plug (1) and drain plug (2), to drain
the remainder of the fluid.
Fig 2: Holder & Rear Flange
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2. Using (special tool #C-3281, Holder, Flange) (1), remove the rear flange (2) nut.
Fig 3: Rear Output Flange
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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 4: Encoder & Transfer Case
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4. Remove encoder screws and the encoder from the transfer case.
Fig 5: Shift Shaft Snap Ring
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5. Remove the shift shaft snap ring from the transfer case.
Fig 6: Shift Motor
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6. Remove shift motor bolts and the shift motor from the transfer case.
Fig 7: Shift Motor O-Ring
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7. Remove the o-ring from the shift motor.

Fig 8: Shift Motor Seal
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8. Using a suitable pry tool, remove shift motor seal from the transfer case.
Fig 9: Worm Shaft Snap Ring
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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 10: Worm Shaft
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10. Remove the worm shaft from the transfer case

Fig 11: Transfer Case
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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 12: Remove/Install Output Shaft Thrust Washer
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12. Remove the output shaft thrust washer.

Fig 13: Remove/Install Oil Pump Assembly
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13. Remove the oil pump assembly.

Fig 14: Oil Tube O-Ring
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14. Remove oil tube (1) from the oil pump and remove the o-ring (2).
Fig 15: Pick-Up Magnet
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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 16: Worm Shaft Drive Gear
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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 17: Clutch Cam
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17. Remove the clutch cam.

Fig 18: Clutch Upper Snap Ring
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18. Remove the clutch upper snap ring.

Fig 19: Clutch Shim
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19. Remove the clutch shim.

Fig 20: Thrust Collar
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20. Remove the thrust collar.

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

Fig 22: Upper Bearing
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22. Remove the upper thrust bearing.

Fig 23: Upper Shift Lever
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23. Remove the upper shift lever.

Fig 24: Shift Lever Balls
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24. Remove the shift lever balls.

Fig 25: Lower Shift Lever
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25. Remove the lower shift lever.

Fig 26: Lower Bearing
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26. Remove the lower thrust bearing.

Fig 27: Lower Race
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27. Remove the lower thrust bearing race.

Fig 28: Clutch Apply Piston
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28. Remove the clutch apply piston.
NOTE:
For ease of installation note the assembly orientation of the 4 identical springs.
Fig 29: Removing/Installing Clutch Return Springs
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29. Remove the clutch return springs.

Fig 30: Clutch Pack
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30. Remove the clutch pack.

Fig 31: Clutch Inner Hub
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31. Remove the inner clutch hub.

Fig 32: Clutch Hub Snap Ring
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32. Remove the clutch drum thrust washer (1) and snap ring (2).
Fig 33: Clutch Drum
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33. Remove the outer clutch drum from the mainshaft drive sprocket.
Fig 34: Front Drive Sprocket, Mainshaft Drive Sprocket And Drive Chain
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34. Remove the front drive sprocket, mainshaft drive sprocket and drive chain as one.
Fig 35: Shift Shaft Spacer
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35. Remove the shift shaft spacer.

Fig 36: Shift Shaft
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36. Remove the shift shaft.

Fig 37: Removing/Installing Main Shaft
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37. Remove the main shaft from the transfer case.

Fig 38: Removing/Installing Front Output Shaft Snap Ring
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38. Remove the retaining snap ring from the front output shaft.
Fig 39: Removing/Installing Front Output Shaft
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39. Remove the front output shaft from the transfer case.
Fig 40: Removing/Installing Input Gear Snap Ring
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40. Using a suitable pry tool or a screw mounted in a slide hammer, remove the input gear seal.
Remove the input gear snap ring.
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
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.
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
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the holes are not blocked. Failure to follow this caution may result in transfer case damage.
Fig 1: Exploded View Of MP3010 Transfer Case

1 - BOOT CLAMP
2 - BOOT
3 - BOOT CLAMP
4 - OIL SLINGER
5 - FRONT OUTPUT SEAL
6 - FRONT CASE
7 - FRONT OUTPUT / FRONT INPUT BEARING
8 - DOWEL
9 - MAGNET
10 - FRONT OUTPUT SHAFT
11 - GEMINI CHAIN
12 - OIL PUMP PICK-UP TUBE
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13 - OIL PUMP TUBE O-RING
14 - DRIVE SPROCKET
15 - RETAINING RING
16 - REAR CASE BEARING
17 - REAR OUTPUT BEARING
18 - REAR CASE
19 - CASE BOLTS
20 - WORM SHAFT NEEDLE BEARING
21 - WORM SHAFT
22 - WORM SHAFT BEARING
23 - WORM SHAFT BEARING RETAINING RING
24 - E-CLIP
25 - WORM SHAFT SEAL
26 - SHIFT MOTOR
27 - SHIFT MOTOR BOLTS
28 - ENCODER BOLTS
29 - ENCODER
30 - REAR OUTPUT SHAFT SEAL
31 - BUSHING
32 - ENCODER SEAL
33 - ID TAG
34 - RETAINING RING
35 - BREATHER TUBE
36 - FILL / DRAIN PLUG
37 - CASE BOLTS
38 - OIL PUMP
39 - RETAINING RING
40 - SHIM
41 - THRUST COLLAR
42 - THRUST WASHER
43 - NEEDLE BEARING
44 - SHIFT BEARING ACTUATOR
45 - OUTER BEARING RACE
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46 - NEEDLE BEARING
47 - UPPER LEVER
48 - LEVER BALLS
49 - LOWER LEVER
50 - NEEDLE BEARING
51 - THRUST WASHER
52 - CLUTCH PISTON
53 - CLUTCH SPRING
54 - BEARING
55 - RETAINING RING
56 - WORM DRIVE GEAR
57 - REACTION PLATE
58 - FRICTION PLATE
59 - CLUTCH CAM
60 - SPACER
61 - CLUTCH HUB
62 - RETAINING RING
63 - POSITION SENSOR COUPLER
64 - RETAINING RING
65 - BUSHING
66 - CLUTCH DRUM
67 - SHIFT SHAFT
68 - BUSHING
69 - SHIFT RAIL
70 - MAIN SHAFT
71 - PLUG
72 - HUB SPROCKET
73 - BUSHING
74 - DRIVE SPROCKET
75 - RETAINING RING
76 - THRUST WASHER
77 - RETAINING RING
78 - BAR CODE LABEL
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79 - INPUT SHAFT SEAL
80 - BOLT STUDS
Fig 2: Remove Input Gear Bearing
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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 3: Identifying Front Output Shaft Bearing
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3. Using a suitable pry tool or a screw mounted in a slide hammer, remove the front output shaft
seal.
4. Using (special tool #6061, Installer, Cup) inverted, and (special tool #C-4171, Driver Handle,
Universal), remove front output shaft bearing.
5. Start front output shaft bearing in case. Then seat bearing with (special tool #C-4171, Driver
Handle, Universal) (3) and (special tool #C-4210, Installer, Seal) (2).
6. Install the front output shaft seal using (special tool #6560, Installer, Bearing Cup).
Fig 4: Installing Rear Output Shaft Seal
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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 (special tool #L-4408, Installer,
Bearing) (2) inverted and (special tool #C-4171, Driver Handle, Universal) (1).
9. Install the rear output shaft bearing into the rear case using (special tool #6061, Installer, Cup)
inverted and (special tool #C-4171, Driver Handle, Universal).
Fig 5: Shift Shaft Bearing Snap Ring
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10. Remove shift shaft bearing snap ring.

Fig 6: Removing Shift Shaft Bearing
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11. Remove shift shaft bearing using (special tool #C-4171, Driver Handle, Universal) (1) and
(special tool #5066, Installer, Bushing) (2).
Fig 7: Shift Shaft Bearing Installation
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12. Install shift shaft bearing using (special tool #C-4171, Driver Handle, Universal) and (special
tool #5066, Installer, Bushing) inverted.
Fig 8: Shift Shaft Bearing Snap Ring
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13. Install shift shaft bearing snap ring.

Fig 9: Removing Front Output Shaft Rear Bearing
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14. Remove front output shaft rear bearing from housing using (special tool #7794-A, Remover,
Seal) (1) and (special tool #C-637, Slide Hammer, Universal) (2).
Fig 10: Installing Front Output Shaft Rear Bearing
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15. Install front output shaft rear bearing in housing using (special tool #6061, Installer, Cup) (2)
inverted and (special tool #C-4171, Driver Handle, Universal) (2).
Fig 11: Removing/Installing Front Output Shaft
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16. Install the front output shaft flange (2) into the front housing (1).
Fig 12: Removing/Installing Front Output Shaft Snap Ring
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17. Install the front output shaft snap ring.

Fig 13: Removing/Installing Input Gear Snap Ring
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18. Install the input gear snap ring.

Fig 14: Installing Input Shaft Seal
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19. Using (special tool #9672, Installer, Seal) (2) and (special tool #C-4171, Driver Handle,
Universal) (1), install a new input shaft seal.
Fig 15: Removing/Installing Main Shaft
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20. Install the mainshaft into the transfer case.

Fig 16: Shift Shaft
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21. Install the shift shaft.

Fig 17: Shift Shaft Spacer
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22. Install the shift shaft spacer.

Fig 18: Front Drive Sprocket, Mainshaft Drive Sprocket And Drive Chain
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NOTE:
There is a blue link on one side of the chain. This blue link MUST be installed
facing upward.
23. Install the front drive sprocket, mainshaft drive sprocket and drive chain as one.
Fig 19: Clutch Drum
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24. Install the outer clutch drum onto the mainshaft drive sprocket.
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25. Install the clutch drum snap ring (2) and thrust washer (1).
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26. Install the inner clutch hub.

Fig 22: Clutch Pack
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27. Starting with a friction disc and ending with a friction disc, install the clutch pack.
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28. Install the clutch return springs.

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29. Install the clutch apply piston with the lettering up and the stepped face down.
Fig 25: Lower Race
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30. Install the lower bearing race with the race fitting into the grove in the reaction plate.
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31. Install the lower bearing.

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32. Install the lower shift lever.

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33. Install the shift lever balls into their pockets.

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34. Install the upper shift lever.

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35. Install the upper thrust bearing.

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36. Install the upper bearing race.

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37. Install the thrust collar.

Fig 33: Clutch Shim
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38. Install the clutch shim.

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39. 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 35: Clutch Cam
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40. 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 36: Worm Shaft Drive Gear
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41. Install the worm drive gear.

Fig 37: Pick-Up Magnet
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42. Install the magnet into the magnet pocket.

Fig 38: Oil Tube O-Ring
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43. Install a NEW O-ring (2) onto the oil pump tube (1).
Fig 39: Remove/Install Oil Pump Assembly
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44. Lubricate the oil tube O-ring with MOPAR® ATF+4 and install the tube into the oil pump.
45. Install the oil pump assembly.

Fig 40: Remove/Install Output Shaft Thrust Washer
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46. Install the output shaft thrust washer.

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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).
47. Apply bead of Mopar® Gasket Maker, or equivalent, to one of the mating surfaces of the front
or rear housing.
48. Install the rear housing onto the front housing. Install the housing bolts and tighten housing
bolts in a crisscross pattern. Refer to TORQUE SPECIFICATIONS .
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 42: Worm Shaft
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49. 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 43: Worm Shaft Snap Ring
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50. Install the worm shaft snap ring.

Fig 44: Shift Motor Seal
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51. Using a suitable installer, install the shift motor seal.

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52. Install a NEW O-ring onto the shift motor.

Fig 46: Shift Motor
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NOTE:
Note the orientation of the shift motor shaft to the worm gear shaft.
53. Install the shift motor onto the transfer case. Install the shift motor bolts and tighten the shift
motor bolts. Refer to TORQUE SPECIFICATIONS .
Fig 47: Shift Shaft Snap Ring
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NOTE:
It may be necessary to pull out on the shift shaft to properly seat the shift shaft snap
ring.
54. Install the shift shaft snap ring.

Fig 48: Arrow & Alignment Mark
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55. 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.
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56. Install the encoder onto the rear transfer case housing. Install the encoder screws and tighten.
Refer to TORQUE SPECIFICATIONS .
Fig 50: Rear Cover Seal Installation
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57. Using a suitable pry tool or a screw mounted in a slide hammer, remove the rear cover seal.
58. Using (special tool #C-4210, Installer, Seal) (2) and (special tool #C-4171, Driver Handle,
Universal) (1), install the rear cover seal.
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59. Install the companion flange onto the mainshaft.

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60. Using (special tool #C-3281, Holder, Flange) (1), install the rear output flange (2) nut and
tighten. Refer to TORQUE SPECIFICATIONS .
INSTALLATION > INSTALLATION

Fig 1: Transfer Case, Transmission & Bolts
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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). Refer to TORQUE SPECIFICATIONS .
6. Connect the transfer case vent hose to the transfer case.

Fig 2: Fill Plug & Drain Plug
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7. Install the skid plate, if equipped.
8. Remove transmission jack and support stand.
9. Connect front propeller shaft and install rear propeller shaft. Refer to SHAFT, DRIVE, FRONT,
INSTALLATION and SHAFT, DRIVE, REAR, INSTALLATION .
10. Fill transfer case with correct fluid. Refer to STANDARD PROCEDURE .
11. Connect the shift motor and encoder electrical connectors.
12. Lower vehicle.
13. Disengage the manual park release.
14. If replacing the transfer case, Drivetrain Control Module (DTCM), or both, use the scan tool to
perform the Non-Volatile Memory Reset procedure.
15. Perform the DTCM verification test. Refer to STANDARD PROCEDURE .
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).
SPECIAL TOOLS > SPECIAL TOOLS
5066 - Installer, Bushing

(Originally Shipped In Kit Number(s) 9975.)
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6061 - Installer, Cup
(Originally Shipped In Kit Number(s) 6303, 6822.)
6560 - Installer, Bearing Cup

(Originally Shipped In Kit Number(s) 6671, 9698.)
7794-A - Remover, Seal

9672 - Installer, Seal

(Originally Shipped In Kit Number(s) 9696, 9697, 9698.)
C-3281 - Holder, Flange
(Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299,
9299CC, 9299CC, 9300A-CAN.)
C-4171 - Driver Handle, Universal

(Originally Shipped In Kit Number(s) 9202, 9202A-CAN, 9202CC, 9299,
9299CC, 9299CC, 9300A-CAN.)
C-4210 - Installer, Seal
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C-637 - Slide Hammer, Universal

L-4408 - Installer, Bearing
CLUTCH > DISASSEMBLY > DISASSEMBLY

Fig 1: Exploded View Of Clutch Components
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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
NOTE:

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1. Remove the clutch upper snap ring.

Fig 3: Clutch Shim
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2. Remove the clutch shim.

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3. Remove the thrust collar.

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4. Remove the upper thrust bearing race.

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5. Remove the upper thrust bearing.

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6. Remove the upper shift lever.

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7. Remove the shift lever balls.

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8. Remove the lower shift lever.

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9. Remove the lower thrust bearing.

Fig 11: Lower Race
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10. Remove the lower bearing race.

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11. Remove the clutch apply piston.
NOTE:
For ease of installation note the assembly orientation of the 4 identical springs.
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12. Remove the clutch return springs.
NOTE:
For ease of installation note the assembly configuration of the clutch plates and
friction discs.
Fig 14: Clutch Pack
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13. Remove the clutch pack.

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14. Remove the inner clutch hub.

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15. Remove the clutch hub thrust washer (1) and snap ring (2).
Fig 17: Clutch Drum
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16. Remove the outer clutch drum from the main shaft and drive sprocket.
CLUTCH > ASSEMBLY > ASSEMBLY

Fig 1: Exploded View Of Clutch Components
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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
NOTE:

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Fig 2: Clutch Drum
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1. Install the outer clutch drum onto the main shaft and drive sprocket.
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2. Install the clutch hub snap ring (2) and thrust washer (1).
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3. Install the inner clutch hub.

Fig 5: Clutch Pack
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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.

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5. Install the clutch return springs.

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6. Install the clutch apply piston with the lettering up and the stepped face down.
Fig 8: Lower Race
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7. Install the lower thrust bearing race.

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8. Install the lower thrust bearing.

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9. Install the lower shift lever.

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10. Install the shift lever balls into their pockets.

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11. Install the upper shift lever.

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12. Install the upper thrust bearing.

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13. Install the upper thrust bearing race.

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14. Install the thrust collar.

Fig 16: Clutch Shim
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15. Install the clutch shim.

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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.
Fig 1: Drain And Fill Plugs
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1 - FILL PLUG
2 - DRAIN PLUG
1. Raise vehicle. Ensure that the vehicle is level on the hoist.
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 the proper specifications. Refer to TORQUE
SPECIFICATIONS .
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 the proper specifications. Refer to TORQUE
SPECIFICATIONS .
7. Lower vehicle.
MOTOR, SHIFT > DESCRIPTION > DESCRIPTION
Fig 1: MP3010 Transfer Case, Shift Motor & Position Sensor
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The overall function of the shift motor (1) is an electromechanical device consisting of a DC permanent
magnet motor and a position holding brake. The shift motors function is to move the clutch lever found in
the transfer case. The operating current of the shift motor under stall conditions is 30 amps maximum, at
22 degrees C (72° F) with 13.5 volts, at the motor leads.
MOTOR, SHIFT > OPERATION > OPERATION
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Torque splitting between the front and rear output shafts in the transfer case occurs when a Pulse Width
Modulated (PWM) voltage is supplied to the shift motor (1) by the Drive Train Control Module (DTCM). A
linear analog position sensor (encoder) (3) located on the rear transfer case housing and provides the
DTCM with the motor's angular, rotational position. With this information, the DTCM continuously knows
the position of the motor, and therefore allows it to accurately control the operation of the motor,
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 and
clutch 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 outputs. When normal force is applied
to this clutch pack, torque is transferred to equalize speed differences between the front and rear axles.
MOTOR, SHIFT > REMOVAL > REMOVAL
Fig 1: Shift Motor
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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.

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4. Remove the o-ring seal from the shift motor.
MOTOR, SHIFT > INSTALLATION > INSTALLATION

Fig 1: Shift Motor
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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 the proper specifications. Refer to
TORQUE SPECIFICATIONS .
4. Install the electrical wiring harness connector onto the shift motor.
SEAL, INPUT SHAFT, FRONT > 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.
SEAL, INPUT SHAFT, FRONT > INSTALLATION > INSTALLATION
NOTE:
Fig 1: Installing Input Shaft Seal
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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
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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.
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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.
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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.
SEAL, OUTPUT SHAFT, REAR > INSTALLATION > INSTALLATION
NOTE:

Fig 1: Installing Rear Output Shaft Seal
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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).
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2. Install the rear output shaft flange onto the output shaft.
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3. Using Holder (special tool #C-3281, Holder, Flange) (1), install the rear companion flange (2)
nut. Tighten the nut to the proper specifications. Refer to TORQUE SPECIFICATIONS .
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

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The transfer case encoder (3) 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. When the DTCM
is not in sleep mode, it must supply 5 VDC (+/- 0.5 v) to the sensor and monitor 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 turned to the OFF position. The sensor is mechanically linked to the shaft of the cam. The
mode sensor draws less than 20 mA of current during operation.
SENSOR, MODE > 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 AUTO (ACTIVE) 2.00 - 4.75
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SENSOR, MODE > REMOVAL > REMOVAL
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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.
SENSOR, MODE > INSTALLATION > INSTALLATION

Fig 1: Arrow & Alignment Mark
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1. Align arrow (1) on the encoder shaft with alignment mark (2) prior to installing the encoder.
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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 the proper specifications. Refer to TORQUE
SPECIFICATIONS .
4. Install the electrical wiring harness connector onto the encoder.

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DESCRIPTION > DESCRIPTION

OPERATION > OPERATION

CONDITION POSSIBLE CAUSE CORRECTION

2) Internal transfer case 2) Repair or replace components

2) Transfer case vent closed or 2) Clean or replace vent as

SPECIFICATIONS > SPECIFICATIONS

ATF+4 1.35L (2.85 Pints)(1)

(1) Fill to bottom edge of the fill plug hole.

DESCRIPTION N.m Ft. Lbs. In. Lbs. COMMENTS

Bolts, Clevis Bracket to

Plug, Clutch Lever Rail (Detent) 27 20 -

Bolts, Case Half 27 20 -

Bolts, Rear Cover 27 20 -

Nuts, T-case mount stud 35 26 -

Bolts, Shift Motor 13 9 -

Screws, Encoder 6.5 - 58

REMOVAL > REMOVAL

Fig 1: Fill Plug & Drain Plug

4. Support transmission (3) with jack stand.

5. Remove skid plate, if equipped.

8. Disconnect transfer case vent hose.

9. Support transfer case (1) with transmission jack.

10. Secure transfer case to jack with chains.

11. Remove bolts (3) attaching transfer case to transmission (2).

13. Remove transfer case from under vehicle.

DISASSEMBLY > DISASSEMBLY

Fig 1: Exploded View Of MP3010 Transfer Case

Courtesy of CHRYSLER GROUP, LLC

5 - FRONT OUTPUT SEAL

7 - FRONT OUTPUT / FRONT INPUT BEARING

10 - FRONT OUTPUT SHAFT

12 - OIL PUMP PICK-UP TUBE

16 - REAR CASE BEARING

17 - REAR OUTPUT BEARING

20 - WORM SHAFT NEEDLE BEARING

22 - WORM SHAFT BEARING

23 - WORM SHAFT BEARING RETAINING RING

25 - WORM SHAFT SEAL

27 - SHIFT MOTOR BOLTS

30 - REAR OUTPUT SHAFT SEAL

36 - FILL / DRAIN PLUG

44 - SHIFT BEARING ACTUATOR

45 - OUTER BEARING RACE

56 - WORM DRIVE GEAR

63 - POSITION SENSOR COUPLER

78 - BAR CODE LABEL

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

10. Remove the worm shaft from the transfer case

12. Remove the output shaft thrust washer.

13. Remove the oil pump assembly.

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

16. Remove the worm drive gear.

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.