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Transfer Case - NV140

Fig 1: Removing Input Gear Bearing
GC0027432Courtesy of CHRYSLER LLC
1 - HANDLE C-4171
2 - INSTALLER 8693A
3 - FRONT HOUSING
  1. Remove the input shaft bearing from the front case (3) with Handle C-4171 (1) and Installer 8693A (2).
    Fig 2: Installing Input Gear Bearing
    GC0027433Courtesy of CHRYSLER LLC
    1 - INPUT GEAR BEARING
    2 - FRONT CASE
  2. Install the new input gear bearing into the front case (3) using Installer 8152 (2), inverted, and Handle C-4171 (1).
    Fig 3: Removing Front Output Shaft Bearing
    GC0027431Courtesy of CHRYSLER LLC
    1 - HANDLE C-4171
    2 - INSTALLER 7829A
    3 - FRONT HOUSING
  3. Using Installer 7829A (2) and Handle C-4171 (1), remove front output shaft bearing from the front case (3).
    Fig 4: Installing Front Output Shaft Bearing
    GC0027430Courtesy of CHRYSLER LLC
    1 - HANDLE C-4171
    2 - INSTALLER 8152
    3 - FRONT HOUSING
  4. Start front output shaft bearing in the front case. Using Installer 8152 (2), inverted, and Handle C-4171 (1), seat the bearing in the front case (3).
    Fig 5: Installing Rear Output Shaft Bearing
    GC0027429Courtesy of CHRYSLER LLC
    1 - HANDLE C-4171
    2 - INSTALLER 8152
    3 - REAR HOUSING
  5. Remove the main shaft rear bearing from the rear case using Installer 5066 and Handle C-4171.
  6. Install the new main shaft rear bearing into the rear case (3) using Installer 8152 (2), inverted, and Handle C-4171 (1).
    Fig 6: Remove/Install Front Output Shaft and Flange
    GC0027421Courtesy of CHRYSLER LLC
    1 - FRONT HOUSING
    2 - FRONT OUTPUT SHAFT
  7. Install a new front output shaft seal with Installer 6560.
  8. Install the front output shaft assembly (2) into the front case (1) and the front output shaft front bearing.
    Fig 7: Remove/Install Front Output Shaft Retaining Ring
    GC0027420Courtesy of CHRYSLER LLC
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  9. Install the retaining ring (2) onto the front output shaft (1).
    Fig 8: Removing/Installing Input Gear
    GC0027419Courtesy of CHRYSLER LLC
    1 - FRONT HOUSING
    2 - INPUT GEAR
  10. Install the input gear (2) into the front case (1).
  11. Install the new input shaft seal with Installer 9672 and Handle C-4171.
    Fig 9: Removing/Installing Retainer at Mode Hub
    GC0006010Courtesy of CHRYSLER LLC
    1 - MODE HUB
    2 - MODE HUB RETAINER
  12. Lubricate mainshaft splines with recommended transmission fluid.
    NOTE: Replace the mode hub retainer if the legs were distorted during removal.
  13. Install the mode hub retainer (2) onto the mode hub (1).
    Fig 10: Removing/Installing Mode Hub and Retainer
    GC0006009Courtesy of CHRYSLER LLC
    1 - DIFFERENTIAL ASSEMBLY
    2 - MODE HUB AND RETAINER
  14. Install the mode hub (2) and mode hub retainer onto the differential assembly (1). Make sure the retainer is fully seated onto the differential.
    Fig 11: Removing/Installing Differential
    GC0027418Courtesy of CHRYSLER LLC
    1 - DIFFERENTIAL ASSEMBLY
    2 - MAINSHAFT
  15. Install the differential assembly (1) onto the mainshaft (2).
    Fig 12: Removing/Installing Differential Snap-Ring
    GC0027417Courtesy of CHRYSLER LLC
    1 - DIFFERENTIAL SNAP-RING
  16. Install the differential snap-ring (1). See Fig 12.
    Fig 13: Remove/Install Chain Guide
    GC0027424Courtesy of CHRYSLER LLC
    1 - DRIVE CHAIN GUIDE
  17. Install the drive chain guide (1) onto the transfer case.
    Fig 14: Remove/Install Chain Guide Screws
    GC0027423Courtesy of CHRYSLER LLC
    1 - SCREWS
    2 - FRONT CASE
  18. Install the screws (1) to hold the chain guide rail to the front case (2). Tighten the screws to 5-8 N.m (44-71 in. lbs.).
    Fig 15: Removing/Installing Input Gear Thrust Washer
    GC0027427Courtesy of CHRYSLER LLC
    1 - THRUST WASHER
    2 - INPUT GEAR
  19. Install the input gear thrust washer (1) onto the input gear (2).
    Fig 16: Removing/Installing Mainshaft & Differential Assembly
    GC0027416Courtesy of CHRYSLER LLC
    1 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY
    2 - FRONT HOUSING
    NOTE: Be sure that the input spline is engaged with the differential assembly.
  20. Install the mainshaft and differential assembly (1) into the front case (2) and input gear.
    Fig 17: Remove/Install Front and Rear Drive Sprockets and Drive Chain
    GC0027415Courtesy of CHRYSLER LLC
    1 - FRONT DRIVE SPROCKET
    2 - MAINSHAFT DRIVE SPROCKET
    3 - DRIVE CHAIN
  21. Install the drive sprockets (1, 2) and drive chains (3) as one.
    Fig 18: Front Drive Sprocket Retaining Ring Removal/Installation
    GC0027414Courtesy of CHRYSLER LLC
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  22. Install the front output shaft (1) drive sprocket retaining ring (2).
    Fig 19: Removing/Installing Mode Hub Spacer
    GC0027428Courtesy of CHRYSLER LLC
    1 - OUTPUT SHAFT
    2 - MODE HUB SPACER
    3 - MODE HUB
  23. Install the mode hub spacer (2) onto the output shaft (1) and the mode hub (3).
  24. Install the mainshaft drive sprocket retaining ring onto the mainshaft.
    Fig 20: Removing/Installing Rear Housing
    GC0027422Courtesy of CHRYSLER LLC
    1 - REAR HOUSING
    2 - FRONT HOUSING
  25. Install the transfer case magnet into the magnet pocket.
  26. Apply bead of Mopar® Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3 mm (0.125 inch). Do not use excessive amount of sealer as excess will be displaced into case interior.
  27. Install the rear case (1) onto the front case (2).
    Fig 21: Removing/Installing Rear Housing Bolts
    GC0027413Courtesy of CHRYSLER LLC
    1 - REAR HOUSING
    2 - BOLTS
    3 - FRONT HOUSING
  28. Install the bolts (2) to hold the rear case (1) to the front case (3). Tighten the bolts at the alignment dowel locations first. Tighten the bolts to 27 N.m (20 ft. lbs.).
    Fig 22: Remove/Install Rear Output Shaft Flange
    GC0027412Courtesy of CHRYSLER LLC
    1 - REAR OUTPUT SHAFT FLANGE
    2 - REAR OUTPUT SHAFT
  29. Install a new rear output seal into the rear case with Installer C-3972A.
  30. Install the rear output flange (1) onto the output shaft (2).
    Fig 23: Remove/Install Rear Output Shaft Nut
    GC0027411Courtesy of CHRYSLER LLC
    1 - HOLDER C-3281
    2 - REAR OUTPUT SHAFT FLANGE
  31. Using Holder C-3281 (1), install the rear companion flange (2) nut. Tighten the nut to 122-176 N.m (90-130 ft. lbs.).
    Fig 24: Remove/Install Damper
    GC0027426Courtesy of CHRYSLER LLC
    1 - DAMPER
    2 - REAR HOUSING
  32. Install the transfer case damper (1) onto the rear case (2).
    Fig 25: Remove/Install Damper Bolts
    GC0027425Courtesy of CHRYSLER LLC
    1 - BOLTS
    2 - DAMPER
    3 - REAR HOUSING
  33. Install the bolts (1) to hold the damper (2) to the rear case (3). Tighten the bolts to 27 N.m (20 ft. lbs.).
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