MXT Magna MP1528 Transfer Case

SERVICE MANUAL
SERVICE MANUAL SECTION MXT Magna MP1528 Transfer Case - Service and Electrical Troubleshooting Model: MXT S13038 11/08/2007
S13038 Copyright 11/08/2007 International Truck and Engine Corporation
MXT Magna MP1528 Transfer Case - Service and Electrical Troubleshooting
1. DESCRIPTION
NOTICE The information supplied herein has been furnished by the manufacturer an/or the supplier for use with its product. International Truck and Engine Corporation reprints this information based on representations made to the Company by the manufacturer and/or supplier and is not responsible for any errors or mishaps resulting from such errors or from any misuse of the product. Every user is urged to carefully follow the instructions which accompany the product. Supplier drawings for the special tools that may be required for servicing the transfer case are after the Service Procedures part of this document. These tool drawings may be used for local sourcing/fabrication as required. International Truck and Engine Corporation also may have available a set of these tools for loan to individual dealers. Contact the Service Tools Department by e-mail at toolbox@nav-international.com for information.
S13038
Magna Powertrain USA, Inc.
New Process Gear
Magna Powertrain USA, Inc. New Process Gear, Inc. 6600 New Venture Gear Drive E. Syracuse, New York 13057 USA www.magnapowertrain.com
International MXT
MP1528 Transfer Case Service Procedures
MP1528 Service Instructions
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New Process Gear
T AB L E O F C O N T E N T S
SECTION 1. 2. 3. TRANSFER CASE IDENTIFICATION TAG SUMMARY SUMMARY OF SERVICABLE COMPONENTS TRANSFER CASE SERVICE PROCEDURES A.1 Input Flange Removal A.2 Input Seal Slinger Removal A.3 Input Seal Removal A.4 Input Seal Installation A.5 Input Seal Slinger Installation A.6 Input Flange Installation B.1 Front Output Flange Removal B.2 Front Output Seal Slinger Removal B.3 Front Output Seal Removal B.4 Front Output Seal Installation B.5 Front Output Seal Slinger Installation B.6 Front Output Flange Installation C.1 Rear Output Flange Removal C.2 Rear Output Seal Slinger Removal C.3 Input Seal Removal C.4 Rear Output Seal Installation C.5 Rear Output Seal Slinger Installation C.6 Rear Output Flange Installation D.1 Shift Shaft O-Ring Retainer Removal and Replacement D.2 Shift Shaft O-Ring Removal and Replacement E.1 Electric Actuator (Motor) Removal E.2 Electric Actuator (Motor) Installation F.1 Transfer Case Vent Removal F.2 Transfer Case Vent Installation G.1 Detent Screw / O-ring Assembly Replacement H.1 Transfer Case Fastener Replacement 4. 5. 6. TRANSFER CASE SHIFT POSITIONS TRANSFER CASE MAINTENANCE SCHEDULE AND PROCEDURES APPENDIX Page # 3 4 7 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 36
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1.
TRANSFER CASE IDENTIFICATION TAG SUMMARY
The Magna Powertrain New Process Gear identification tag is attached to the rear housing of the transfer case. Unit specific information is contained on this tag. See figure 1.
Figure 1:
Transfer Case Identification Tag
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2.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
SUMMARY OF SERVICABLE COMPONENTS

Vent P/N 51411 Input / Rear Output Flange P/N 25440 Input / Rear Output Nut P/N 25541 Input Seal Slinger P/N 53317 Front Output Nut P/N 13368 Front Output Flange P/N 25871 Output Seal Slinger P/N 51676 Case Flange Mount Stud P/N 51358 Rear Retainer Mount Stud P/N 51362 Input Seal P/N 51347 Input Mount Stud P/N 26070 Electric Actuator P/N 48408 Motor Screw P/N 17192 Output Seal P/N 24288 Oil Fill / Drain Plug P/N 51412 Detent Screw / O-Ring Assembly P/N 23989 Detent Spring (not shown) P/N 17174 Detent (not shown) P/N 16754 Shift-Shaft O-Ring Retainer P/N 13726 Shift-Shaft O-Ring (not shown) P/N 13725 Transfer Case Controller Module (not shown) P/N 52744
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3.
TRANSFER CASE SERVICE PROCEDURES
NOTE: Unless otherwise noted, all removed parts should be visually inspected and saved for rebuild. For any service performed with the transfer case removed from the vehicle, use pallet asm. P/N PR55462 to properly support the unit. Use care to not damage the input mounting studs when placing the transfer case on the pallet asm.
A.1
Input Flange Removal

1. Remove input flange nut. Use flange spanner wrench P/N PR55463 to hold flange. 2. Place flange removal press jaws under flange and remove flange by turning flange removal press shaft clockwise. See figure A1.
Figure A1:
Input Flange Removal
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A.2
Input Seal Slinger Removal

1. Remove input flange per Input Flange Removal. 2. Use a mallet to remove input seal slinger as shown in figure A2. Use care to avoid damage to the flange. 3. Discard removed input seal slinger.
Figure A2:
Input Seal Slinger Removal
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A.3
Input Seal Removal
1. Remove drain plug and fully drain unit of oil. 2. Remove input seal by gently prying under seal body with seal removal tool (Snap-On stock# YA105 or equivalent) as shown in figure A3. If required, gently pry under the seal flange. Discard removed seal. 3. Visually inspect housing seal bore and lead-in chamfer for any damage.
Figure A3:
Input Seal Removal
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A.4
Input Seal Installation
1. Clean and visually inspect housing input seal bore to ensure no debris or contamination. 2. Apply Perfect Seal sealant or equivalent, as needed, to the metal portion of the seal OD. 3. Align seal to seal bore and start in lead-in chamfer. 4. Place input seal installation tool P/N PR55466 over seal. 5. Seat input seal by driving seal installation tool with a rubber mallet. See figure A4. 6. Visually inspect and clean repair area. 7. Replace drain plug and refill unit with 5.0-5.5 pints of Texaco P/N 1854 Dexron III ATF or approved equivalent. See Transfer Case Fluid Fill for additional information. <!> Caution Use care to ensure that input seal lip is not rolled or otherwise damaged during assembly onto input gear assembly (seal journal).
Figure A4:
Input Seal Installation
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A.5
Input Seal Slinger Installation
1. Place slinger press - base P/N PR53529 in appropriate press. 2. Place slinger on press base, align flange and press flange using input / rear output slinger press tool P/N PR53531 until slinger is flush to flange shoulder, as shown in figure A5.
Figure A5:
Input Seal Slinger Installation
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A.6
Input Flange Installation

1. Align input flange spline to input shaft spline and assemble flange onto shaft. 2. Hold flange using flange spanner wrench P/N PR55463. Install input / rear output nut P/N 25441 to draw down and seat flange onto shaft. Tighten nut to 217-285 N-m (160.1-210.2 lb-ft). See figure A6.
Figure A6:
Input Flange Installation
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B.1
Front Output Flange Removal

1. Remove front output flange nut. Use flange spanner wrench P/N PR55463 to hold flange. 2. Place flange removal press jaws under flange and remove flange by turning flange removal press shaft clockwise. See figure B1.
Figure B1:
Front Output Flange Removal
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B.2
Front Output Seal Slinger Removal

1. Remove front output flange per Front Output Flange Removal procedure. 2. Use a mallet to remove front output seal slinger as shown in figure B2. Use care to avoid damage to the flange. 3. Discard removed front output seal slinger.
Figure B2:
Front Output Seal Slinger Removal
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B.3
Front Output Seal Removal

1. Remove drain plug and fully drain unit of oil. 2. Rem ove front output seal by gently prying under seal body with seal removal tool (Snap-On stock# YA105 or equivalent) as shown in figure B3. If required, gently pry under the seal flange. Discard removed seal. 3. Visually inspect housing seal bore for any damage.
Figure B3: Front Output Seal Removal
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B.4
Front Output Seal Installation

1. Clean and visually inspect housing front output seal bore to ensure no debris or contamination. 2. Apply Perfect Seal sealant or equivalent, as needed, to the metal portion of the seal OD. 3. Align seal to seal bore and start in lead-in chamfer. 4. Place output seal installation tool P/N PR55467 over seal. 5. Seat front output seal by driving seal installation tool with a rubber mallet. See figure B4. 6. Visually inspect and clean repair area. 7. Replace drain plug and refill unit with 5.0-5.5 pints of Texaco P/N 1854 Dexron III ATF or approved equivalent. See Transfer Case Fluid Fill for additional information.
<!> Caution Use care to ensure that front output seal lip is not rolled or otherwise damaged during assembly onto front output shaft (seal journal).
Figure B4:
Front Output Seal Installation
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B.5
Front Output Seal Slinger Installation

1. Place slinger press - base P/N PR53529 in appropriate press. 2. Place slinger on press base, align flange and press flange using front output slinger press tool P/N PR53530 until slinger is flush to flange shoulder, as shown in figure B5.
Figure B5:
Front Output Seal Slinger Installation
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B.6
Front Output Flange Installation
1. Align front output flange spline to front output shaft spline and assemble flange onto shaft. 2. Hold flange using flange spanner wrench P/N PR55463. Install front output nut P/N 13368 to draw down and seat flange onto shaft. Tighten nut to 176-271 N-m (129.8199.9 lb-ft). See figure B6.
Figure B6: Front Output Flange Installation
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C.1
Rear Output Flange Removal

1. Remove output flange nut. Use flange spanner wrench P/N PR55463 to hold flange. 2. Place flange removal press jaws under flange and remove flange by turning flange removal press shaft clockwise. See figure C1.
Figure C1:
Rear Output Flange Removal
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C.2
Rear Output Seal Slinger Removal

1. Remove rear output flange per Rear Output Flange Removal procedure. 2. Use a mallet to remove rear output seal slinger as shown in figure C2. Use care to avoid damage to the flange. 3. Discard removed rear output seal slinger.
Figure C2:
Rear Output Seal Slinger Removal
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C.3
Rear Output Seal Removal

1. Remove drain plug and fully drain unit of oil. 2. Remove rear output seal by gently prying under seal body with seal removal tool (Snap-On stock# YA105 or equivalent) as shown in figure C3. If required, gently pry under the seal flange. Discard removed seal. 3. Visually inspect housing seal bore for any damage.
Figure C3: Rear Output Seal Removal
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C.4
Rear Output Seal Installation

1. Clean and visually inspect housing rear output seal bore to ensure no debris or contamination. 2. Apply Perfect Seal sealant or equivalent, as needed, to the metal portion of the seal OD. 3. Align seal to seal bore and start in lead-in chamfer. 4. Place output seal installation tool P/N PR55467 over seal. 5. Seat rear output seal by driving seal installation tool with a rubber mallet. See figure C4. 6. Visually inspect and clean repair area. 7. Replace drain plug and refill unit with 5.0-5.5 pints of Texaco P/N 1854 Dexron III ATF or approved equivalent. See Transfer Case Fluid Fill for additional information.
<!> Caution Use care to ensure that rear output seal lip is not rolled or otherwise damaged during assembly onto output shaft (seal journal).
Figure C4:
Rear Output Seal Installation
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C.5
Rear Output Seal Slinger Installation

1. Place slinger press - base P/N PR53529 in appropriate press. 2. Place slinger on press base, align flange and press flange using input / rear output slinger press tool P/N PR53531 until slinger is flush to flange shoulder, as shown in figure C5.
Figure C5:
Rear Output Seal Slinger Installation
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C.6
Rear Output Flange Installation

1. Align rear output flange spline to rear output shaft spline and assemble flange onto shaft. 2. Hold flange using flange spanner wrench P/N PR55463. Install input / rear output nut P/N 25441 to draw down and seat flange onto shaft. Tighten nut to 217-285 N-m (160.1-210.2 lb-ft). See figure C6.
Figure C6:
Rear Output Flange Installation
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D.1 Shift Shaft O-Ring Retainer Removal and Replacement

1. Remove electric actuator per electric actuator removal procedure. 2. Pry shift shaft o-ring retainer from counterbore using a pick or small screwdriver. See figure D1 for detail. 3. Reverse procedure to install. <!> Caution Use care to ensure that o-ring counterbore is not damaged during disassembly.
Figure D1:
Shift Shaft O-Ring Retainer Removal and Replacement
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D.2 Shift Shaft O-Ring Removal and Replacement

1. Remove electric actuator per electric actuator removal procedure. 2. Remove shift shaft o-ring retainer per shift shaft oring retainer removal procedure. 3. Pry shift shaft o-ring from counterbore using a pick or small screwdriver. See figure D2 for detail. 4. Reverse procedure to install. Apply uniform pressure when installing replacement o-ring to prevent rolling or creasing. Apply transfer case lubricant (ATF) to the replacement o-ring as needed to aid assembly. Clean excess oil from mounting face before reinstalling electric actuator (motor). <!> Caution Use care to ensure that o-ring counterbore is not damaged during disassembly. Use care to ensure o-ring is not creased or otherwise dam aged during reassembly.
Figure D2:
Shift Shaft O-Ring Removal and Replacement
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E.1 Electric Actuator (Motor) Removal

1. Disconnect all electrical connections from electric actuator (if replacement is done in vehicle). 2. Remove (3) M8 electric actuator screws. See figure E1. 3. Pull electric actuator straight off pilot and splined shaft to disengage.
Figure E1:
Electric Actuator (Motor) Removal
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E.2 Electric Actuator (Motor) Installation

1. Lightly grease housing motor face. 2. Align electric actuator to shift shaft spline, front housing adapter pilot counterbore and (3) actuator motor screw holes. NOTE: Missing tooth in actuator drive spline must be aligned to missing tooth on shift shaft. 3. Slide onto shift shaft, into counterbore and seat to mounting face. 4. Install (3) electric actuator mounting screws. Assemble all screws until they are lightly seated to the electric actuator screw boss faces. 5. Tighten (3) electric actuator mounting screws to 16.0-24.0 N-m (11.8-17.7 Lb-ft). See figure E2. <!> Caution Do not fully torque any electric actuator screws before all have been seated against the electric actuator screw boss faces. Failure to evenly tighten these fasteners may cause excess misalignment and electric actuator failure.
Figure E2:
Electric Actuator (Motor) Installation
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F.1 Transfer Case Vent Removal

1. Grasp transfer case vent with locking pliers or equivalent. Rotate while pulling vent straight out of the transfer case. See figure F1. <!> Caution Excessive rocking or bending of the vent during removal may damage the front housing machined vent hole.
Figure F1:
Transfer Case Vent Removal
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F.2 Transfer Case Vent Installation

1. Apply Loctite 680 (or equivalent) sealant to the outside of the vent where it engages the housing bore. 2. Align and hand start vent into housing. 3. Use vent installation tool P/N PR55464 and mallet to fully seat vent as shown in figure F2. 4. Wipe any excess sealant from vent and housing after installation.
Figure F2:
Transfer Case Vent Installation
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G.1 Detent Screw / O-ring Assembly Replacement

1. Remove drain plug and fully drain unit of oil. 2. Rem ove detent screw / o-ring assembly. 3. Clean and visually inspect detent screw threaded hole. 4. Install replacement detent screw / o-ring assembly. Tighten detent screw to 16.0-24.0 N-m (11.8-17.7 Lbft). 5. See figures G1 and G2 for detail.
Figure G1:
Detent Screw Assembly
Figure G2:
Detent Screw Asm Detail
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H.1 Transfer Case Fastener Replacement

See the chart below for serviceable fasteners, replacement part numbers and assembly torques. Further detail regarding serviceable fasteners can be found in section 2 of this manual.
Fastener Name Case flange mount stud Rear retainer mount stud Input mount stud
Part Number 51358 51362 26070
Assembly Requirement Torque to 23.7-30.5 N-m (17.5-22.5 Lb-ft) Torque to 27.0-34.0 N-m (19.9-25.1 Lb-ft) Drive to 30 +/- 0.64 mm installed height
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4.
Transfer Case Shift Positions
Transfer case shift position can be confirmed by the position of the shift shaft missing tooth. See figure 4. Mode can be confirmed by rotating the front output; Front output rotates freely 2W D Front output does not rotate (locked to input)
4W D
Use sector shaft socket P/N PR53877 to make any required shift position changes when the electric actuator is removed from the unit. The sector shaft socket can be used to confirm a units physical ability to shift if required in the course of issue troubleshooting. Transfer case shift position must match the electric actuator position before reassembly.
Figure 4: Transfer Case Shift Positions (missing tooth position)
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5. TRANSFER CASE MAINTENANCE SCHEDULE AND PROCEDURES

Fluid level check procedure Transfer Case lubricant level should be checked after every 10000 miles of vehicle operation or at routine vehicle service, whichever comes first. NOTE: check Vehicle should be on a level surface during fluid
1. Remove transfer case fill plug. 2. Use finger or allen wrench to confirm fluid level is within 3/8 of the bottom of the fill hole. Add fluid as needed per fluid fill procedure if below this level. 3. Replace fill plug and tighten to 20-34 N-m (14.825.1 Lb-ft). <!> Caution Do Not Use Impact W rench On Fill Or Drain Plugs. To the Threads / Plugs May Result. Damage
Fluid drain and replacement procedure Transfer case lubricant is to be drained and replaced after every 60000 miles of vehicle operation. NOTE: check Vehicle should be on a level surface during fluid
1. Remove transfer case fill and drain plugs and fully drain unit. 2. Clean, visually inspect and replace drain plug. Tighten to 20-34 N-m (14.8-25.1 Lb-ft). 3. Fill unit with 5.0-5.5 pints of Texaco P/N 1854 Dexron III ATF or approved equivalent. Use finger to confirm fluid level is within of the bottom of the fill hole. Add fluid as needed to achieve this level. 4. Replace fill plug and tighten to 20-34 N-m (14.825.1 Lb-ft).
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Transfer case / vehicle underbody wash Cautions When pressure washing the transfer case or vehicle underbody, use caution to avoid any high pressure water stream directly onto any transfer case seal lips, motor connection, vent or vent tube interface. Direct high pressure streams on these surfaces / component may lead to water intrusion into the transfer case.
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6. APPENDIX Transfer Case Serviceable Component Torque Chart

Component Stud - Rear Case Bolt - Retainer Stud - Rear Retainer Plug - Fill Plug - Drain Bolt - Motor Nut - Rear Output Nut - Front Input Nut - Front Output Adapter - Motor Screw Asm - Detent Part Number 51358 25625 51362 51412 51412 17192 25441 25411 13368 31915 23989 Assembly Torque N-m Lbf-ft 23.7-30.5 17.5-22.5 27.0-34.0 19.9-25.1 27.0-34.0 19.9-25.1 20.0-34.0 14.8-25.1 20.0-34.0 14.8-25.1 16.0-24.0 11.8-17.7 217.0-285.0 160.1-210.2 217.0-285.0 160.1-210.2 176.0-271.0 129.8-199.9 27.0-34.0 19.9-25.1 16.0-24.0 11.8-17.7
Approved Transfer Case Fluids

1. Texaco P/N 1854 Dexron III ATF
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International MXT MP1528 Transfer Case Electrical Troubleshooting Procedures
Table of Contents:
1.General
1.1. Definitions 1) Actuator 2) Module 3) Transfer Case 4) Mode Shift 5) Range Shift 1.2. Required Tools
2.Troubleshooting
2.1. From 2H to 4H 2.2. From 4H to 4L 2.3. From 4L to 4H 2.4. From 4H to 2H 2.5. From 2H to 4L 2.6. From 4L to 2H 2.7. Indicator Test Procedure 2.8. Diagnostic Test Procedure 2.9. Diagnostic Connector Test Procedure
3.References
3.1. Mechanization Diagram 3.2. Actuator 1) Mounting Position 2) Interface Connector 3) Actuator Position Voltages 3.3. Module 1) Pinout Diagram 2) Module I/O Voltages 3) Effects of Faults 3.4. Switch
1.General
1.1. Definitions 1) Actuator
An electrical motor that controls the physical shifting inside the transfer case. It is also known as Transfer Case Rotary Actuator.
2) Module
A control module that includes a microprocessor that controls the actuator. It is also known as Transfer Case Control Module.
3) Transfer Case
A device that receives power from the transmission and sends it to both the front and rear axles.
4) Mode Shift
A shift between any of the high range modes (2H, 4H).
5) Range Shift
A shift between H range and L range. Any shift into or out of 4L is considered a Range Shift.
1.2. Required Tools

1) A tool to verify that the module is communicating on the Controller Area Network (CAN). 2) A tool to verify that the module is communicating the correct transmission position. 3) A tool to verify that the module is communicating the correct vehicle speed. 4) A multimeter to check the voltage and to conduct continuity tests.
2.Troubleshooting
2.1. Step: 1 2 3
From 2H to 4H Condition: Yes:

Proceed to the next step.
No:
Switch to the 4H position. Proceed to the indicator test procedure. (Section 2.7) Proceed to the diagnostic test procedure. (Section 2.8)
Is the selector switch in the 4H position?
Does the 2H indicator remain solid with the 4H Proceed to the next step. indicator flashing? Does the 4H indicator remain solid with the 2H Test completed. indicator turned off?
2.2. Step: 1 2 3 4 5 6
From 4H to 4L Condition: Yes:

Proceed to the next step. Proceed to the next step. Proceed to the next step.
No:
Switch to the 4L position. Put the vehicle into neutral. Slow down the vehicle to 3 mph or below. Proceed to the indicator test procedure. (Section 2.7) Proceed to the next step. Proceed to the next step.
Is the selector switch in the 4L position? Is the vehicle in neutral? (Use a tool for verification.) Is the vehicle below 3 mph? (Use a tool for verification.)
Does the 4H indicator remain solid with the 4L Proceed to the next step. indicator flashing? Does the 4L indicator remain solid with the 4H Test completed. indicator turned off? Does the 4L indicator stop flashing after 30 seconds with the 4H indicator turned solid? Check that the vehicle conditions from steps 1 and 2 were met, and restart the test. Proceed to the diagnostic test procedure. (Section 2.8)
Does the 4L indicator stop flashing before 30 seconds with the 2H or 4H indicator turned solid?
Refer to actuator section of Mechanical Service Manual.
2.3. Step: 1 2 3 4 5
From 4L to 4H Condition: Yes:

No:
Switch to the 4H position. Put the vehicle into neutral. Slow down the vehicle to 3 mph or below. Proceed to the indicator test procedure. (Section 2.7) Proceed to the diagnostic test procedure. (Section 2.8)
Is the selector switch in the 4H position? Is the vehicle in neutral? (Use a tool for verification.) Is the vehicle below 3 mph? (Use a tool for verification.)
Does the 4L indicator remain solid with the 4H Proceed to the next step. indicator flashing? Does the 4H indicator remain solid with the 4L Test completed. indicator turned off?
2.4. Step: 1 2 3
From 4H to 2H Condition: Yes:

No:
Switch to the 2H position. Proceed to the indicator test procedure. (Section 2.7) Proceed to the diagnostic test procedure. (Section 2.8)
Is the selector switch in the 2H position?
Does the 4H indicator remain solid with the 2H Proceed to the next step. indicator flashing? Does the 2H indicator remain solid with the 4H Test completed. indicator turned off?
2.5. Step: 1 2 3 4 5 6
From 2H to 4L Condition: Yes:

No:
Switch to the 4L position. Put the vehicle into neutral. Slow down the vehicle to 3 mph or below. Proceed to the indicator test procedure. (Section 2.7) Proceed to the next step. Proceed to the next step.
Is the selector switch in the 4L position? Is the vehicle in neutral? (Use a tool for verification.) Is the vehicle below 3 mph? (Use a tool for verification.)
Does the 2H indicator remain solid with the 4L Proceed to the next step. indicator flashing? Does the 4L indicator remain solid with the 2H Test completed. indicator turned off? Does the 4L indicator stop flashing after 30 seconds with the 2H indicator turned solid? Check that the vehicle conditions from steps 1 and 2 were met, and restart the test. Proceed to the diagnostic test procedure. (Section 2.8)
Does the 4L indicator stop flashing before 30 seconds with the 2H or 4H indicator turned solid?
Refer to actuator section of Mechanical Service Manual.
2.6. Step: 1 2 3 4 5
From 4L to 2H Condition: Yes:

No:
Switch to the 2H position. Put the vehicle into neutral. Slow down the vehicle to 3 mph or below. Proceed to the indicator test procedure. (Section 2.7) Proceed to the diagnostic test procedure. (Section 2.8)
Is the selector switch in the 2H position? Is the vehicle in neutral? (Use a tool for verification.) Is the vehicle below 3 mph? (Use a tool for verification.)
Does the 4L indicator remain solid with the 2H Proceed to the next step. indicator flashing? Does the 2H indicator remain solid with the 4L Test completed. indicator turned off?
2.7. Step: 1 2 3 4 5
Indicator Test Procedure Condition: Yes:

No:
Turn off the vehicle and wait 5 minutes, then restart the test. Proceed to the next step.
Is the vehicle off?
Turn the key to the RUN position. Did the 2H, 4H, and 4L indicators turned on for 2 seconds during the lamp check sequence?
Proceed to step 4.
Test the continuity between the switch and the Proceed to the next step. module. Verify the switch output voltages (Section 3.4). Are the values correct? Is the wiring harness connected securely on the module and the indicator panel? Verify the module I/O voltages (Section 3.3). Are the values correct? Proceed to the next step.
Replace the switch, and try shifting again. Reconnect the wiring harness, then restart the test. Replace the module, and try shifting again.
Replace indicator lamp, and try shifting again.
2.8. Step: 1 2 3 4 5
Diagnostic Test Procedure Condition: Yes:

No:
Reconnect the wiring harness, and try shifting again. Reconnect the wiring harness, and try shifting again. Proceed to the diagnostic connector test procedure. (Section 2.9) Proceed to the next step. Test the continuity between the module I/O pins and the actuator connector pins. Replace the wiring harness, and try shifting again. Proceed to the next step. Replace the module, and try shifting again.
Is the wiring harness connected securely on the module (Section 3.3)? Is the wiring harness connected securely on the actuator (Section 3.2)? Is there CAN communication? (Use a tool for verification.)
Roll the vehicle below 3 mph and try shifting Test completed. again. Did the transfer case shift successfully? Verify the actuator connector voltages (Section 3.2). Are the values correct? Proceed to the next step.
6 7
Replace the actuator, and try shifting again. Did the transfer case shift successfully? Verify the module I/O voltages (Section 3.3). Are the values correct?
Test completed. The cause of the problem is not electrical. Consult the mechanical troubleshooting manual.
2.9.
Diagnostic Connector Test Procedure
Test case: Diagnostic connector cavity B to ground: Diagnostic connector cavity B to cavity A:
Expected value:
12 1.5V
Cause:
If voltage is missing, check for open or shorts in circuits between diagnostic connector and F6. Also check for blown fuse F6.
12 1.5V
If voltage is missing, check for open in ground circuits between diagnostic connector and ground stud (1851). If voltage is correct, then the diagnostic connector is inoperative. It should be replaced.
Diagnostic connector cavity C to cavity A: Diagnostic connector cavity D to cavity A: (1650) Pin F to ground: (1650) Pin G to ground:
2.5 0.5V
If voltage is missing, check for open in circuits between diagnostic connector and 1939 data link circuits. If voltage is missing, check for open in circuits between diagnostic connector and 1939 data link circuits. (+) data link circuit. If voltage is low, check for open in positive data link circuits. (-) data link circuit. If voltage is low, check for open in negative data link circuits. If voltage is high, check for crossed data link circuits.
2.5 0.5V
Approximately 4V Approximately 1V
Extended Description: Battery voltage required to operate the diagnostic circuits is supplied from fuse F6 on circuit A98 to diagnostic connector (1650) pin B. Ground is supplied from ground stud connector (1851) to diagnostic connector (1650).
3. References
3.1. Mechanization Diagram
3.2. Actuator 1) Mounting Position
Actuator mounting position
Actuator
2) Interface Connector
Yazaki P/N w/CPA: 7283-5927-10 - 2.8 x 0.8 HPA Series, Dark Grey - Water and airtight sealed connector configuration - Female terminals 7116-4150-02 & 7116-4152-02 copper alloy material - Similar to 8-pin male connector assembly: 7282-5574-10 (Polarity A type)
Connector Pin: 1 2 3 4 5 6 7 8
Signal Description:
Encoder Supply Encoder Signal Encoder Return Motor A Signal Motor B Signal -
Module Pin:
J1-9 J1-3 J1-10 J3-C J3-D -
AWG# for Pigtail Option:

20 20 20 14 14 -
3) Actuator Position Voltages
Mode: High Target (Encoder Signal Pin J1-3): Low Target (Encoder Signal Pin J1-3): 2HI 4HI 4LO
4.423V 3.533V 1.703V 4.137V 3.247V 1.3V
3.3. Module 1) Pinout Diagram
NPG 52744 module pinout diagram
NPG 52744 module
2) Module I/O Voltages Selector Switch at Selector Switch at Selector Switch at 2HI: 4HI: 4LO: Pin J1-2 (Mode Switch Supply): Pin J1-3 (Encoder Signal): Pin J1-6 (2HI Lamp): Pin J1-9 (Encoder Supply): Pin J1-10 (Encoder Return): Pin J1-11 (Mode Switch Select): Pin J1-12 (4HI Lamp): Pin J1-13 (4LO Lamp):
4.805V 5.091V 4.137V 4.423V 0V 4.805V 5.091V 0V 2.9V 3.3V 4.805V 5.091V 3.247V 3.533V 4.805V 5.091V 0V 3.8V 4.1V 0V 4.805V 5.091V 1.3V 1.703V 4.805V 5.091V 0V 4.3V 4.6V 0V
3) Effects of Faults Open Pin J1-2 (Mode Switch Supply): Pin J1-3 (Encoder Signal):
No shift due to the switch not being operational.
Short to Ground
Short to Battery (+12V)

No shift due to no encoder No shift due to no encoder No shift due to encoder feedback. feedback. error. LED lights up regardless of position. LED not operational.
Pin J1-6 (2HI Lamp): LED not operational. Pin J1-9 (Encoder Supply): Pin J1-10 (Encoder Return): Pin J1-11 (Mode Switch Select): Pin J1-12 (4HI Lamp): Pin J1-13 (4LO Lamp): Pin J3-C (MOTOR A): Pin J3-D (MOTOR B):
No shift due to no encoder No shift due to no encoder No shift due to encoder supply voltage. supply voltage. Possibly error. causing a fuse to blow. No shift due to no encoder Normal operation. return. No shift due to the switch not being operational. LED not operational. LED not operational. No shift due to no power to motor. No shift due to the switch not being operational. LED lights up regardless of position. LED lights up regardless of position. Motor will only shift in one direction. No shift due to no encoder return. Possibly causing a fuse to blow. No shift due to the switch not being operational. LED not operational. LED not operational. Motor will only shift in one direction automatically and stop. No further shifts can be done. Motor will only shift in one direction automatically and stop. No further shifts can be done..
No shift due to no power to motor.
Motor will only shift in one direction.
3.4. Switch
2HI: Pin 3 (Mode Switch Supply): Pin 2 (Mode Switch Select):

4.805V 5.091V 2.9V 3.3V
4HI:
4.805V 5.091V 3.8V 4.1V
4LO:
4.805V 5.091V 4.3V 4.6V

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SERVICE MANUAL

S13038 Copyright 11/08/2007 International Truck and Engine Corporation

MXT Magna MP1528 Transfer Case - Service and Electrical Troubleshooting

Magna Powertrain USA, Inc.

New Process Gear

MP1528 Service Instructions

Magna Powertrain USA, Inc.

New Process Gear

MP1528 Service Instructions

Magna Powertrain USA, Inc.

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TRANSFER CASE IDENTIFICATION TAG SUMMARY

Transfer Case Identification Tag

MP1528 Service Instructions

Magna Powertrain USA, Inc.

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SUMMARY OF SERVICABLE COMPONENTS

MP1528 Service Instructions

Magna Powertrain USA, Inc.

New Process Gear

MP1528 Service Instructions

Magna Powertrain USA, Inc.

New Process Gear

MP1528 Service Instructions

Magna Powertrain USA, Inc.

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TRANSFER CASE SERVICE PROCEDURES

Input Flange Removal

Input Flange Removal

MP1528 Service Instructions

Magna Powertrain USA, Inc.

New Process Gear

Input Seal Slinger Removal

Input Seal Slinger Removal

MP1528 Service Instructions

Magna Powertrain USA, Inc.

New Process Gear

Input Seal Removal

Input Seal Removal

MP1528 Service Instructions

Magna Powertrain USA, Inc.

New Process Gear

Input Seal Installation

Input Seal Installation

MP1528 Service Instructions

Magna Powertrain USA, Inc.

New Process Gear

Input Seal Slinger Installation

Input Seal Slinger Installation

MP1528 Service Instructions

Magna Powertrain USA, Inc.

New Process Gear

Input Flange Installation

Input Flange Installation

MP1528 Service Instructions

Magna Powertrain USA, Inc.

New Process Gear

Front Output Flange Removal

Front Output Flange Removal

MP1528 Service Instructions

Magna Powertrain USA, Inc.

New Process Gear

Front Output Seal Slinger Removal