Mopar 52123025AB Transfer Case

Overhauling of a transfer case is challenging and requires the disassembling and reassembling of many small parts. Select fit spacers and snap rings are used to take precise measurements of clearance in which adjustments can be made if need be. Even though it is possible for a skilled do-it-yourselfer to remove or install a transfer case, you should still consider having transmission repair shop perform the overhaul. Dealership parts departments and automotive stores might carry rebuilt transfer cases. However, an inexperienced mechanic can rebuild one using the right tools and following step-by-step process. The essential tools include: snap-ring pliers, slide hammer, bearing puller, pin punches, dial indicator-perhaps hydraulic press too. Additionally, a firm working bench or vice stand may be necessary for support purposes also for transmission repairs stand. In order to ensure appropriate reassembly when taking apart a machine notes have to be well taken care of by recording everything carefully while disassembling it all down.The broken part must first be known before examining it.

In advance of commencing this process, move the transfer case into 2WD or AWD. Detach the cable(s) from the negative battery terminal(s). Lift the vehicle and fasten it firmly on jackstands. When equipped, eliminate the skid plate and drain the lubricant from the transfer case. Disconnect if provided all vacuum/vent lines, electrical connectors from that transfer case. On manual shift models, disconnect shift lever rod from grommet in transfer case shift lever or floor mounted shift lever arm for electric shift models disconnect transfer case shift motor and transfer case sensor. Get rid of front and rear driveshafts. Hold up transmission with a transmission jack. Sustain transfer case by chains or tie-down straps using a transmission jack. Take out bolts/nuts attaching transfer-case to transmission Remove lastly wires as well as hoses must be separated from transfer case then move Jack along with transfer cases towards cars back till it clears off off transmission after which lower it so that input shaft is free then remove it From beneath cars Remove all gasket material at leftovers of trans RTV sealant should be applied to both sides of transaxle adapter to prevent any leekage With jack holding onto this device, raise it back behind gearbox and slide forward carefully until input shaft mates output shaft Install bolts/nuts attaching TC with Transmission Safely chain should be taken off then remove jacking which supports TC Place back cross member if removed Bring out transmission jack under trans Install propeller shafts Reconnect all vacuum/vent lines Use all electrical connectors at appropriate places In manual shift models; adjust linkage by connecting two points: floor-mounted shifter's arm between shifter rod and TC shifter On electrically shifted vehicles; connect these plugs to engine control unit Refill TC with lube Put on protective plate (if any) Under frame; consequently lower car after removing stands Reset negative battery terminals Check for proper operation during road test and reveal leakages if any.