MP143 Transfer Case - Assembly

ASSEMBLY




MP143 EXPLODED VIEW








Typical Removal Of Input Gear Bearing





1. Remove the input shaft bearing from the front case (3) with Handle C-4171 (1) and Installer 8693 (2).
.



Typical Installation Of Input Gear Bearing





2. Install the new input gear bearing into the front case (3) using Installer 8152 (2), inverted, and Handle C-4171 (1).




Typical Removal Of Front Output Shaft Bearing





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




Typical Installation of Front Output Shaft Bearing





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).










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 8245 (2), and Handle C-4171 (1).










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.










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

10. Install the new input shaft seal with Installer 9672 and Handle C-4171.




TYPICAL CHAIN GUIDE RAIL





11. Install the both drive chain guide rails (1) onto the transfer case.




TYPICAL CHAIN GUIDE RAIL BOLTS





12. Install the screws (1) to hold the both chain guide rails to the front case (2). Tighten the screws to 5-8 Nm (44-71 in.lbs.).










13. Install the mode hub (1) onto the mainshaft (2).










14. Install the mode hub snap ring (1) onto the mainshaft (3).










15. Install the mode sleeve (2) onto the mainshaft (1).










16. Install the mode fork return spring (2) onto the mode fork (1).










17. Install the mode fork assembly (1) onto the mainshaft (2).










18. Install the drive sprockets (1, 2) and drive chain (3) and shift lever as one.










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










20. Install the mainshaft retaining ring (1).










21. Install the transfer case magnet into the magnet pocket.
22. 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.
23. Install the rear case (1) onto the front case (2).










NOTE: Tighten the bolts at the alignment dowel locations first.

24. Apply MOPAR(R) lock and seal onto the transfer case bolts and install the transfer case bolts. Tighten the bolts to 27 Nm (20 ft.lbs.).










NOTE: If reusing the original shift motor be certain to replace the O-ring.

25. Lubricate the shift motor O-ring with trans jell or petroleum jelly.










26. Install the shift motor (1) into the transfer case.





27. Apply MOPAR(R) lock and seal onto the shift motor bolts and install the shift motor bolts into the transfer case. Tighten the shift motor bolts to 12 Nm ( 9 ft.lbs.).










28. Install a new rear output seal into the rear case with Installer C-3972-A.
29. Install the dampener onto the transfer case.










30. Apply MOPAR(R) lock and seal onto the dampener bolts and install the dampener bolts into the transfer case. Tighten the transfer case dampener bolts to 27 Nm (20 ft.lbs.).










31. Install the rear output flange (1) onto the output shaft (2).










32. Using Holder C-3281 (1), install the rear output shaft flange (2) nut. Tighten the nut to 122-176 Nm (90-130 ft.lbs.).




MP143 COMPONENT LOCATIONS





33. Install and tighten drain plug (2) to 12-15 Nm ( 9-11 ft. lbs.).