LEMON Manuals: Even more car manuals for everyone
Home >> Jeep >> 2007 >> Commander Base, 4.7 P, AWD >> Repair and Diagnosis >> Transmission >> Transfer Case >> NV140 Transfer Case (Service Information) >> NV140 - Service Information >> Disassembly >> Transfer Case - NV140

Transfer Case - NV140

Fig 1: Remove/Install Damper Bolts
GC0027425Courtesy of CHRYSLER LLC
1 - BOLTS
2 - DAMPER
3 - REAR HOUSING
  1. Remove the bolts (1) holding the damper (2) to the rear case (3).
    Fig 2: Remove/Install Damper
    GC0027426Courtesy of CHRYSLER LLC
    1 - DAMPER
    2 - REAR HOUSING
  2. Remove the damper (1) from the rear case (2).
    Fig 3: Fill/Drain Plug And I.D. Tag Locations
    GC0027410Courtesy of CHRYSLER LLC
    1 - I.D. TAG
    2 - FILL PLUG
    3 - DRAIN PLUG
  3. Position transfer case on shallow drain pan. Remove drain plug (3) and drain lubricant.
    Fig 4: Remove/Install Rear Output Shaft Nut
    GC0027411Courtesy of CHRYSLER LLC
    1 - HOLDER C-3281
    2 - REAR OUTPUT SHAFT FLANGE
  4. Using Holder C-3281 (1), remove the rear output flange (2) nut.
    Fig 5: Remove/Install Rear Output Shaft Flange
    GC0027412Courtesy of CHRYSLER LLC
    1 - REAR OUTPUT SHAFT FLANGE
    2 - REAR OUTPUT SHAFT
  5. Remove the rear output shaft flange (1) from the main shaft (2). If flange is difficult to remove by hand, remove it with bearing splitter, or with standard two jaw puller. Be sure puller tool is positioned securely on flange.
    Fig 6: Removing/Installing Rear Housing Bolts
    GC0027413Courtesy of CHRYSLER LLC
    1 - REAR HOUSING
    2 - BOLTS
    3 - FRONT HOUSING
  6. Support transfer case so rear case is facing upward and the input gear is not contacting the work surface.
  7. Remove bolts (2) holding front case to rear case (1).
    Fig 7: Removing/Installing Rear Housing
    GC0027422Courtesy of CHRYSLER LLC
    1 - REAR HOUSING
    2 - FRONT HOUSING
    NOTE: Be careful not to damage the front and rear case sealing surfaces.
  8. Loosen rear case with a case splitter or suitable tool to break sealer bead. Insert case splitter or suitable tool only into notches provided at each end of case.
  9. Remove rear case (1) from front case (2).
    Fig 8: Front Drive Sprocket Retaining Ring Removal/Installation
    GC0027414Courtesy of CHRYSLER LLC
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  10. Remove mainshaft drive sprocket retaining ring.
  11. Remove front output shaft drive sprocket retaining ring (2) from the front output shaft (1). See Fig 8.
    Fig 9: 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
  12. Remove the drive sprockets (1, 2) and the drive chains (3) as one.
    Fig 10: Removing/Installing Mainshaft & Differential Assembly
    GC0027416Courtesy of CHRYSLER LLC
    1 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY
    2 - FRONT HOUSING
  13. Remove the mainshaft and differential assembly (1) from the front case (2).
    Fig 11: Removing/Installing Input Gear Thrust Washer
    GC0027427Courtesy of CHRYSLER LLC
    1 - THRUST WASHER
    2 - INPUT GEAR
  14. Remove the input gear thrust washer (1) from the input gear (2).
    Fig 12: Remove/Install Chain Guide Screws
    GC0027423Courtesy of CHRYSLER LLC
    1 - SCREWS
    2 - FRONT CASE
  15. Remove the screws (1) holding the chain guide rails to the front case (2).
    Fig 13: Remove/Install Chain Guide
    GC0027424Courtesy of CHRYSLER LLC
    1 - DRIVE CHAIN GUIDE
  16. Remove the drive chain guide (1) from the transfer case.
    Fig 14: Removing/Installing Differential Snap-Ring
    GC0027417Courtesy of CHRYSLER LLC
    1 - DIFFERENTIAL SNAP-RING
  17. Remove the differential snap-ring (1).
    Fig 15: Removing/Installing Differential
    GC0027418Courtesy of CHRYSLER LLC
    1 - DIFFERENTIAL ASSEMBLY
    2 - MAINSHAFT
  18. Remove the differential assembly (1) from the mainshaft (2).
    Fig 16: Removing/Installing Mode Hub and Retainer
    GC0006009Courtesy of CHRYSLER LLC
    1 - DIFFERENTIAL ASSEMBLY
    2 - MODE HUB AND RETAINER
  19. Remove the mode hub (2) and mode hub retainer from the differential assembly (1).
    Fig 17: Removing/Installing Retainer at Mode Hub
    GC0006010Courtesy of CHRYSLER LLC
    1 - MODE HUB
    2 - MODE HUB RETAINER
  20. Remove the mode hub retainer (2) from the mode hub (1).
    Fig 18: Remove/Install Front Output Shaft Retaining Ring
    GC0027420Courtesy of CHRYSLER LLC
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  21. Remove the retaining ring (2) from the front output shaft (1).
    Fig 19: Remove/Install Front Output Shaft and Flange
    GC0027421Courtesy of CHRYSLER LLC
    1 - FRONT HOUSING
    2 - FRONT OUTPUT SHAFT
  22. Remove the front output shaft assembly (2) from the front case (1) and the front output shaft front bearing.
  23. Remove the front output shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
    Fig 20: Removing/Installing Input Gear
    GC0027419Courtesy of CHRYSLER LLC
    1 - FRONT HOUSING
    2 - INPUT GEAR
  24. Remove the input gear (2) from the front case (1).
  25. Remove the input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
scientia non olet · About LEMON Manuals