Transfer Case Shift Motor

[JohnHaggerty]

Folks,

What's involved with a replacement of the transfer case shift motor? What am I getting into both money wise and level of difficulty?

Thanks

John

 

[sag2]

A word of caution, disconnect both batteries first. If you connect the new motor before installing, it could move out of the shipped position. This should be a 20 minute job.

From service info.

REMOVAL
NOTE: New shift motor assemblies are shipped in the 2WD/AWD position. If a new shift motor assembly will be installed, it will be necessary to shift the transfer case to the 2WD/AWD position prior to motor removal.
1. Raise the vehicle on a suitable hoist.
2. Disengage the wiring connectors from the shift motor and mode sensor.
3. Remove the bolts (3) holding the shift motor and mode sensor assembly (2) onto the transfer case (1).
4. Separate the shift motor and mode sensor assembly (2) from the transfer case.


INSTALLATION
1. Verify that the shift sector o-ring is clean and properly positioned over the shift sector and against the transfer case.
NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned.
2. Position the shift motor and mode sensor assembly (2) onto the transfer case (1).
3. Install the bolts (3) to hold the assembly onto the transfer case. Tighten the bolts to 16-24 N·m (12-18 ft.lbs.).
CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar® Lock AND Seal or Loctite™ 242 to replenish the lock patch material originally found on the bolts
4. Engage the wiring connectors to the shift motor and mode sensor.
5. Refill the transfer case as necessary.
6. Lower vehicle and verify transfer case operation.

 

[JohnHaggerty]

I see a small amount of fluid leak from what I think is a shift motor seal. What fluid flow might I see while changing the shift motor? Must I empty the transfer case first?

My brain says that since I'm in there, empty and refill. If I end up doing this, I will empty first since I've heard grinding noises thru this and am curious if any chips or filings show in the fluid.

Thanks

 

[jhenderson]

Remove the fill plug first. You wouldn't be the first person to empty the transfer case only to discover you can't get the fill plug out.

 

[sag2]

No need to, but while your there I would change the fluid. Most transfer cases never get a fluid change.

 

[Bob4x4]

No need to, but while your there I would change the fluid. Most transfer cases never get a fluid change.

they do in my shop

 

[JohnHaggerty]

Are there alignment issues during replacement? I assume the case should be in 2wd and the motor is slid in as received.

 

[sag2]

Yes, note the caution. As long as you are in 2wd before removal (confirm by doing a tight turn on dry pavement) and you disconnect the batteries (both) the new one ships in 2wd and should slip right in. You may have to wiggle it slightly to get the bolts to start, but if you can't get them started pull it back off and compare the motor positions old to new. You are probably over thinking this repair. It should be very straight forward.