NV140 Transfer Case - Assembly

ASSEMBLY




NV140 EXPLODED VIEW














1. Using a suitable pry tool or a screw mounted in a slide hammer, remove the input shaft seal.
2. Remove the input shaft bearing snap ring.
3. Remove the input shaft bearing from the front case with Handle C-4171 and Installer 5064.
4. Install the new input gear bearing into the front case (3) using Installer 8152 (2), inverted, and Handle C-4171 (1).
5. Install the input shaft bearing snap ring.










6. Remove the front output bearing shaft snap ring.
7. Using Installer 7829-A (2) and Handle C-4171 (1), remove front output shaft bearing from the front case (3).










8. Start front output shaft bearing in the front case. Using Installer 8693(2) inverted, and Handle C-4171 (1), seat the bearing in the front case (3).
9. Install the output bearing shaft snap ring.










10. Remove the main shaft rear bearing from the rear case using Installer 5066 and Handle C-4171.
11. Install the new main shaft rear bearing into the rear case (3) using Installer 8152 (2), inverted, and Handle C-4171 (1).





12. Install the front output shaft assembly (1) into the front case.





13. Install the retaining ring (2) onto the front output shaft (1).





14. Install the new front output shaft seal (1) into position in the transfer case bore (2).





15. Install the front output shaft seal with Installer 10117 (1).





16. Install the new front output shaft seal slinger (1) into position on the output shaft (2).
17. Install the front output shaft seal slinger with Installer 10117.





18. Install the seal boot (2) onto the seal slinger (3)
19. Install a new seal boot clamp onto the seal boot, at the seal slinger, and tighten the clamp with Crimp Tool C-4975A.










20. Install the input gear (2) into the front case (1).





21. Install the input gear retaining ring (1) , if equipped.
22. Install the new input shaft seal with Installer 10118 and Handle C-4171.










23. Lubricate mainshaft splines with recommended transmission fluid.

NOTE: Replace the mode hub retainer if the legs were distorted during removal.

24. Install the mode hub retainer (2) onto the mode hub (1).










25. Install the mode hub (2) and mode hub retainer onto the differential assembly (1). Make sure the retainer is fully seated onto the differential.










26. Install the differential assembly (1) onto the mainshaft (2).










27. Install the differential snap-ring (1).










28. Install the input gear thrust washer (1) onto the input gear (2).






NOTE: Be sure that the input spline is engaged with the differential assembly.

29. Install the mainshaft and differential assembly (1) into the front case (2) and input gear.





30. Install the drive sprockets (1, 3) and drive chains (2) as one.










31. Install the front output shaft (1) drive sprocket retaining ring (2).





32. Install mainshaft drive sprocket retaining ring (2).





33. Install the magnet into the pocket.

NOTE: Apply bead of Mopar(R) 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.





34. Install the rear case (1) onto the front case (2).
35. 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 Nm (20 ft.lbs.).
36. Install the drain plug. Tighten the drain plug to 20-34 Nm (15-25 ft.lbs.)