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MP140 Transfer Case - Service Information: Diagnosis Dodge Nitro I

Transfer Case 7 illustrations ~783 words

INSPECTION-TRANSFER CASE MP140

Inspect the case for cracks, porous spots, worn bores, or damaged threads. Damaged threads can be repaired with Helicoil® thread inserts. However, the case will have to be replaced if it exhibits any type of damage or wear.

Scheme 2

Scheme 2: ASSEMBLY-TRANSFER CASE - MP140
Scheme 2: ASSEMBLY-TRANSFER CASE - MP140
1 - HANDLE C-4171
2 - INSTALLER 8693A
3 - FRONT HOUSING

Scheme 3

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Scheme 3

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Scheme 4

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Scheme 5

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Scheme 6
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Scheme 7

Scheme 8

Scheme 8
Scheme 8
  1. Remove the input shaft bearing from the front case (3) with Handle C-4171 (1) and Installer 8693A (2). 1 - INPUT GEAR BEARING 2 - FRONT CASE
  2. Install the new input gear bearing into the front case (3) using Installer 8152 (2), inverted, and Handle C-4171 (1). 1 - HANDLE C-4171 2 - INSTALLER 7829A 3 - FRONT HOUSING
  3. Using Installer 7829A (2) and Handle C-4171 (1), remove front output shaft bearing from the front case (3). 1 - HANDLE C-4171 2 - INSTALLER 8152 3 - FRONT HOUSING
  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). 1 - HANDLE C-4171 2 - INSTALLER 8152 3 - REAR HOUSING
  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 8152 (2), inverted, and Handle C-4171 (1).
  7. Install a new rear output seal into the rear case with Installer C-3972A. 1 - FRONT HOUSING 2 - FRONT OUTPUT SHAFT
  8. Install a new front output shaft seal with Installer 6560.
  9. Install the front output shaft assembly (2) into the front case (1) and the front output shaft front bearing. 1 - FRONT OUTPUT SHAFT 2 - RETAINING RING
  10. Install the retaining ring (2) onto the front output shaft (1). 1 - FRONT HOUSING 2 - INPUT GEAR
  11. Install the input gear (2) into the front case (1).
  12. Install the new input shaft seal with Installer 9672 and Handle C-4171. 1 - DIFFERENTIAL ASSEMBLY
  13. Install the mode hub (2) onto the differential assembly (1). 1 - DIFFERENTIAL ASSEMBLY 2 - MAINSHAFT
  14. Install the differential assembly (1) onto the mainshaft (2). 1 - DIFFERENTIAL SNAP-RING
  15. Install the differential snap-ring (1). see scheme 32 1 - DRIVE CHAIN GUIDE
  16. Install both drive chain guide (1) onto the transfer case. 1 - SCREWS 2 - FRONT CASE
  17. Install the screws (1) to hold both chain guide rail to the front case (2). Tighten the screws to 5-8 N.m (44-71 in.lbs.). 1 - THRUST WASHER 2 - INPUT GEAR
  18. Install the input gear thrust washer (1) onto the input gear (2). 1 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY 2 - FRONT HOUSING NOTE: Be sure that the input spline is engaged with the differential assembly.
  19. Install the mainshaft and differential assembly (1) into the front case (2) and input gear. 1 - FRONT DRIVE SPROCKET 2 - MAINSHAFT DRIVE SPROCKET 3 - DRIVE CHAIN
  20. Install the drive sprockets (1, 2) and drive chains (3) as one. 1 - FRONT OUTPUT SHAFT 2 - RETAINING RING
  21. Install the front output shaft (1) drive sprocket retaining ring (2). 1 - OUTPUT SHAFT 2 - MODE HUB SPACER 3 - MODE HUB
  22. Install the mode hub spacer (2) onto the output shaft (1) and the mode hub (3).
  23. Install the mainshaft drive sprocket retaining ring onto the mainshaft. 1 - REAR HOUSING 2 - FRONT HOUSING
  24. Install the transfer case magnet into the magnet pocket.
  25. Apply bead of Mopar® 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.
  26. Install the rear case (1) onto the front case (2). 1 - REAR HOUSING 2 - BOLTS 3 - FRONT HOUSING
  27. 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 N.m (20 ft.lbs.). 1 - DAMPENER
  28. Install the dampener (1) onto the rear case. 1 - DAMPENER BOLTS 2 - REAR CASE
  29. Install the bolts (1) to hold the damper (2) to the rear case (3). Tighten the bolts to 27 N.m (20 ft.lbs.). 1 - OUTPUT SHAFT FLANGE 2 - MAIN SHAFT
  30. Install the rear output flange (1) onto the output shaft (2). 1 - HOLDER TOOL C-3281 2 - OUTPUT SHAFT FLANGE 3 - DAMPENER
  31. Using Holder C-3281 (1), install the rear companion flange nut. Tighten the nut to 122-176 N.m (90-130 ft.lbs.). 1 - I.D. TAG 2 - FILL PLUG 3 - DRAIN PLUG
  32. Install and tighten drain plug (3) to 20-34 N.m (15-25 ft. lbs.)

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