NV140 Transfer Case - Disassembly

DISASSEMBLY




NV140 EXPLODED VIEW








NV140 DRAIN AND FILL PLUGS





1. Position transfer case on shallow drain pan. Remove drain plug (3) and drain lubricant.






NOTE: Be careful not to damage the front and rear case sealing surfaces.

2. Support transfer case so rear case is facing upward and the input gear is not contacting the work surface.
3. Remove bolts holding the rear case (1) to the front case (2).
4. 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.
5. Remove rear case (1) from front case (2).





6. Remove the magnet from the pocket.










7. Remove mainshaft drive sprocket retaining ring.
8. Remove front output shaft drive sprocket retaining ring (2) from the front output shaft (1).





9. Remove the mainshaft drive sprocket (1) retaining ring (2).





10. Remove the drive sprockets (1, 3) and the drive chains (2) as one.





11. Remove the mainshaft and differential assembly (1) from the input gear (2).










12. Remove the input gear thrust washer (1) from the input gear (2).





13. Remove the front propeller shaft seal boot (1) retaining clamp (2).





14. Remove the front propeller shaft seal boot (2) from the front output shaft slinger (3).





15. Using a suitable hammer and chisel, strike the seal slinger (2) in three equally spaced locations.

NOTE: The indentations (2) should appear as shown.





16. Remove the seal slinger (1) from the front output shaft.





17. Using a suitable pry tool or a screw mounted in a slide hammer, remove the front output shaft seal (1).





18. Remove the front output shaft retaining ring (2) from the front output shaft (1).





19. Remove the front output shaft (1).










20. Remove the differential snap-ring (1).










21. Remove the differential assembly (1) from the mainshaft (2).










22. Remove the mode hub (2) and mode hub retainer from the differential assembly (1).










23. Remove the mode hub retainer (2) from the mode hub (1).





24. Remove the input gear assembly (2) retaining ring (1) from the front case, if equipped.










25. Remove the input gear (2) from the front case (1).
26. Remove the input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.