In previous issues of Keep Those Trannys Rolling, we looked at the Magna Performance MP3010 transfer case control system and the diagnostic routines needed to keep this four-wheel drive system rolling down the road.
In this issue, we’re going to look inside the transfer case, to see how to disassemble, repair, and reassemble it.
The Auto 4WD mode provides an on-demand torque biasing wet clutch, which allows the transfer case control system to adjust the AWD application through variable software calibrations. This provides more features, such as flexible adapt ready position and variable clutch preload torque levels which enhance the performance of the AWD system.
This technology allows for speed-dependent torque transfer to enhance driving performance, prevent crow-hopping or binding at low speeds, and improve vehicle stability at higher speeds.
Now let’s take a look inside the MP3010 transfer case.
SECURING TRANSFER CASE
For ease of disassembly and reassembly, use a transmission/ transfer case holding fixture to secure the transfer case assembly to the bench.
REMOVING EXTERNAL COMPONENTS
Begin by draining the transfer case oil and removing the external components.
These components include:
- Access hole plugs
- Fill and drain plugs
- Transfer case 2/4 wheel drive actuator (encoder/motor) assembly
- Gear position sensor
- Vehicle speed sensor (figure 1)
- Remove the 17 Torx bit transfer case bolts securing the two transfer case halves together (figure 2).
- Release the transfer case rear output shaft outer retaining snap ring from the transfer case rear output shaft rear bearing assembly before splitting the transfer case halves apart. Use a set of snap ring pliers to release the snap ring through the rear case access holes (figure 3). Once you’ve released the snap ring, you can pry the transfer case halves apart using opposing pry bars along the case bosses.
Now you should be able to see the front output shaft/gear assembly, the actuator shaft and cam assembly, the drive chain, the oil pump, and the output shaft assembly (figure 4).
- Remove the oil pump suction pipe and the actuator shaft gear assembly.
- Remove the output shaft assembly, the drive chain, and the actuator shaft and cam assembly as a complete unit.
- Remove the front output shaft/gear assembly.
- Clean and inspect individual components.
TRANSFER CASE HALVES
- Clean the transfer case halves.
- Inspect the transfer case halves for signs of wear, damage, cracks, or warpage. Repair or replace as needed.
- Check actuator shaft bearing assemblies located in both case halves (figure 5) and replace as needed.
- Inspect case bearings and seals and replace as needed.
To make it easier to disassemble and reassemble the output shaft assembly, secure the output shaft assembly in a holding fixture (vise) or place the assembly through a hole in your workbench (figure 6).
- Remove the output shaft rear bearing snap ring.
- Use an arbor press or extended jaw type puller to remove the output shaft rear bearing assembly.
- Remove the output shaft bearing retaining ring and the speed sensor reluctor wheel.
- Remove the transfer case oil pump, the drive sprocket retaining ring, the drive sprocket rear spacer, and the drive sprocket assembly.
- Remove the drive sprocket front spacer and the 2/4 wheel drive clutch snap ring and shim.
- Remove the four-wheel drive clutch assembly, which includes the clutch hub, eight friction plates, seven steel plates, four pressure plate springs, and an apply plate, as a complete unit (figure 7).
- Remove the actuator lever washer, the actuator lever thrust bearing assembly #2, the #2 actuator lever assembly, the three actuator balls, the #1 actuator lever assembly, and the actuator lever thrust bearing assembly #1 (figure 8).
- Clean and inspect all components for wear and repair or replace as needed.
- Reassemble the rear output shaft assembly.
Never disassemble the oil pump; it is not serviceable. Inspect the oil pump for wear or binding and replace as needed.
The high/low shift components include:
- Actuator cam snap ring
- Actuator cam spacer
- Actuator cam
- Actuator shaft
- Actuator shaft gear
The 2/4 range shift components include a 2/4 shift fork and actuator assembly.
Clean and inspect all components, and repair or replace as needed.
FOUR-WHEEL DRIVE CLUTCH ASSEMBLY
- Clutch hub
- Eight friction plates
- Seven steel plates
- Four pressure plate springs
- Apply plate
Disassemble, clean, and inspect the four-wheel drive clutch assembly, and repair or replace worn components as needed.
FRONT OUTPUT SHAFT/GEAR ASSEMBLY
- Clean and inspect the front output shaft/gear assembly.
- Check gear teeth for damage and splines for wear and repair or replace as needed.
The drive chain is not serviceable. Inspect the drive chain for being kinked, stretched, or any sign of damage and replace as needed.
- Secure the front transfer case half to your workbench using your holding fixture.
- Install the front output shaft/gear assembly.
- Install the output shaft assembly, the drive chain, and the actuator shaft and cam assembly as a complete assembly. Partially install the actuator shaft, levers, and output shaft assembly into the case while installing the drive chain onto the front output shaft/gear assembly (figure 9).
- Install the oil pump suction pipe and the actuator shaft gear.
- Prepare the rear transfer case half for assembly onto the front case half using a set of snap ring pliers to release the snap ring through the rear case access holes. With snap ring released (figure 10), carefully install the rear transfer case half onto the front transfer case half.
- Install the 17 Torx bit transfer case bolts to secure the two transfer case halves together (figure 11).
- Install the access hole plugs, the drain and fill plugs, the transfer case 2/4 wheel drive actuator (encoder/ motor) assembly, the gear position sensor, and the vehicle speed sensor.
Well, there you have it: an inside look at the Magna Performance MP3010 transfer case. With a better understanding of how this transfer case works, you should have no problem keeping those trannys rolling.