NV146 Transfer Case - Assembly
ASSEMBLY
1. Remove the input shaft bearing from the front case (3) with Handle C-4171 (1) and Installer 8693 (2).
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2. Install the new input gear bearing into the front case (3) using Installer 8152 (2), inverted, and Handle C-4171 (1).
3. Using Installer 7829-A (2) and Handle C-4171 (1), remove front output shaft bearing from the front case (3).
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 rear main shaft bearing retaining ring from inside the rear housing.
6. Remove the rear output shaft bearing from the rear case using Installer 5066 (2) and Handle C-4171 (3).
7. Install the rear output shaft bearing into the rear case using Remover/Installer 8281 (2) and Handle C-4171 (3).
8. Install the rear output shaft bearing retaining ring into the rear housing, from inside the rear housing.
9. Install a new front output shaft seal with Installer 6560.
10. Install the front output shaft (2) into the front housing (1) and the front output shaft front bearing.
11. Install the retaining ring (2) onto the front output shaft (1).
12. Install the new input shaft seal with Installer 9672 and Handle C-4171.
13. Install the shift sector (2) into the rear housing (1).
14. Install the retaining ring (2) onto the shift sector shaft (1).
15. Install the oil pick-up tube o-ring (2) into the rear housing (1).
16. Prime the oil pickup tube by pouring a little oil into the tube before installation.
17. Install the oil pick-up tube and screen (1) into the rear housing.
18. Position the clutch lever assembly (1) into the rear housing.
19. Install the clutch lever rail (2) into the rear housing (1).
20. Install the clutch lever rail plug (1) into the rear housing. Tighten the plug to 27 Nm (20 ft.lbs.).
21. Install the drive chain guide (1) onto the transfer case.
22. Install the screws (2) to hold the chain guide rail (1) to the front housing. Tighten the screws to 5-8 Nm (44-71 in.lbs.).
23. Install the mainshaft into the input bearing.
24. Install the front drive sprocket (3), main shaft drive sprocket (1), and drive chain (2) as one.
25. Install the front drive sprocket retaining ring (2) onto the front output shaft (1).
26. Install the snap-ring (2) to hold the clutch drum/mainshaft sprocket assembly (1) to the mainshaft.
27. Install the inner clutch hub (2) over the mainshaft and into the clutch drum (1).
28. Install a friction disc (2) over the inner clutch hub and into the clutch drum (1).
29. Install a steel disc (2) over the inner clutch hub and into the clutch drum (1). Continue in this manner until all the friction and steel discs are installed.
30. Install the wave spring (2) onto the main shaft (1).
CAUTION: When installing the clutch pressure plate, make sure that the wave spring remains piloted on the underside of the plate. Check that the spring does not protrude between the plate and the mainshaft.
31. Install the clutch pressure plate (2) onto the main shaft (1) and clutch assembly.
32. Install the thrust bearing (2) onto the main shaft (1).
33. Install the thrust bearing support plate (2) onto the main shaft (1).
NOTE: The clutch pressure plate must be engaged with the inner drum and held down when installing the retaining ring.
34. Install the thrust bearing support plate retaining ring (2) onto the main shaft (1).
35. Rotate the thrust bearing support plate (1) so that the tab (2) is pointed between the two bolt holes (3) as shown.
36. 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 and potentially clog the oil pump screen.
37. Verify that the tab on the thrust bearing support plate is aligned with the housing alignment dowel furthest from the front output shaft.
38. Install the rear housing (1) into the front housing (2).
39. Install the bolts (2) to hold the rear housing (1) to the front housing (3). Tighten the bolts at the dowel locations first, then the remainder of the bolts in a criss-cross pattern. Tighten the bolts to 27 Nm (20 ft.lbs.).
Lubricate the oil pump components with the correct transfer case fluid before installation.
40. Install the oil pump outer rotor (2) onto the main shaft (1) and into the rear housing (3).
41. Install the oil pump inner rotor (2) onto the main shaft (1) and into the rear housing (3).
42. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of rear housing as shown (2). Keep sealer bead width to maximum of 3 mm (1/8 inch). Do not use excessive amount of sealer as excess could be displaced into the oil pump.
43. Install a new rear output shaft seal into the rear cover with Installer C-3972-A.
44. Install the rear cover (1) onto the rear housing (2).
45. Install the bolts (3) holding the rear cover (2) onto the rear housing (1). Tighten the bolts at the dowel locations first, then the remainder of the bolts in a criss-cross pattern. Tighten the bolts to 27 Nm (20 ft.lbs.).
46. Verify that the shift motor o-ring is clean and properly positioned inside the machined o-ring groove of the shift motor.
NOTE: Verify that the missing tooth (2) in the shift motor drive spline (1).
NOTE: .and the transfer case drive spline (1) missing tooth (2) are aligned. It may be necessary to manually shift the transfer case if the shift motor and transfer case shaft are not aligned.
47. Install the shift motor (1) onto the shift sector (2) and the transfer case (3).
48. Install the bolts (1) to hold the shift motor (2) to the transfer case. Tighten the bolts to 27 Nm (20 ft.lbs.).
49. Install the rear output flange (1) onto the main shaft (2).
50. Using Holder C-3281 (1), install the rear output flange (2) nut. Tighten the nut to 122-176 Nm (90-130 ft.lbs.).