MP140 Transfer Case - Service Information: Other Dodge Nitro I

TRANSFER CASE -MP140

Full-time 4-wheel drive distributes torque to all wheels under normal driving conditions. The transfer case uses an open (unlocked) center differential to divide engine torque nearly evenly between the front and rear axles - 48 percent to the front axle and 52 percent to the rear axle. The open differential allows the front and rear drive shafts to rotate at different speeds to account for front and rear wheels traveling different distances when turning. Because the drive shafts can rotate at different speeds, the vehicle can remain in full-time 4-wheel drive mode continuously - even on dry pavement - without threat of damage to the drive train. The standard-equipment ESP, which combines ABS, Traction Control, and Electronic Roll Mitigation, enhances traction by modulating torque among all wheels as necessary - providing resistance to any wheel that is slipping while allowing torque to flow to the wheels with traction.

Scheme 9

1. Raise vehicle. CAUTION: Do not allow propeller shafts to hang at attached end. Damage to joint can result.
2. Remove the front and rear propeller shafts. Refer to «REMOVAL»(ref-306145-S17464238962008120900000).
3. Support transmission with jack stand.
4. Remove rear crossmember and skid plate, if equipped.
5. Disconnect transfer case vent hose (4). (Scheme 9)
6. Disconnect the wiring connector from the shift motor, if necessary.
7. Support transfer case with transmission jack and secure with chains.
8. Remove nuts (2) attaching transfer case (1) to transmission (3).
9. Pull transfer case and jack rearward to disengage transfer case.
10. Remove transfer case from under vehicle.

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

1. Position transfer case on shallow drain pan. Remove drain plug (2) and drain lubricant. 1 - HOLDER TOOL C-3281 2 - OUTPUT SHAFT FLANGE 3 - DAMPENER
2. Using Holder C-3281 (1), remove the rear output flange nut. 1 - OUTPUT SHAFT FLANGE 2 - MAIN SHAFT
3. Remove the rear output shaft flange (1) from the main shaft (2). If flange is difficult to remove by hand, remove it with bearing splitter, or with standard two jaw puller. Be sure puller tool is positioned securely on flange. 1 - DAMPENER BOLTS 2 - REAR CASE
4. Remove the bolts holding the dampener to the rear case. 1 - DAMPENER
5. Remove the dampener (1) from the rear case. 1 - REAR HOUSING 2 - BOLTS 3 - FRONT HOUSING
6. Support transfer case so rear case is facing upward and the input gear is not contacting the work surface.
7. Remove bolts (2) holding front case to rear case (1). 1 - REAR HOUSING 2 - FRONT HOUSING NOTE: Be careful not to damage the front and rear case sealing surfaces.
8. 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.
9. Remove rear case (1) from front case (2). 1 - FRONT OUTPUT SHAFT 2 - RETAINING RING
10. Remove mainshaft drive sprocket retaining ring.
11. Remove front output shaft drive sprocket retaining ring (2) from the front output shaft (1). (Scheme 17) 1 - FRONT DRIVE SPROCKET 2 - MAINSHAFT DRIVE SPROCKET 3 - DRIVE CHAIN
12. Remove the drive sprockets (1, 2) and the drive chains (3) as one. 1 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY 2 - FRONT HOUSING
13. Remove the mainshaft and differential assembly (1) from the front case (2). 1 - THRUST WASHER 2 - INPUT GEAR
14. Remove the input gear thrust washer (1) from the input gear (2). 1 - SCREWS 2 - FRONT CASE
15. Remove the screws (1) holding both chain guide rails to the front case (2). 1 - DRIVE CHAIN GUIDE
16. Remove both drive chain guide rails (1) from the transfer case. 1 - DIFFERENTIAL SNAP-RING
17. Remove the differential snap-ring (1). 1 - DIFFERENTIAL ASSEMBLY 2 - MAINSHAFT
18. Remove the differential assembly (1) from the mainshaft (2). 1 - DIFFERENTIAL ASSEMBLY
19. Remove the mode hub (2) and mode hub retainer from the differential assembly (1).
20. Remove the mode hub retainer (2) from the mode hub (1). 1 - FRONT OUTPUT SHAFT 2 - RETAINING RING
21. Remove the retaining ring (2) from the front output shaft (1). 1 - FRONT HOUSING 2 - FRONT OUTPUT SHAFT
22. Remove the front output shaft assembly (2) from the front case (1) and the front output shaft front bearing.
23. Remove the front output shaft seal with a suitable pry tool or a screw mounted in a slide hammer. 1 - FRONT HOUSING 2 - INPUT GEAR
24. Remove the input gear (2) from the front case (1).
25. Remove the input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.

CLEANING-TRANSFER CASE MP140

The use of crocus cloth is permissible where necessary, providing it is used carefully. When used on shafts, or valves, use extreme care to avoid rounding off sharp edges. Sharp edges are vital as they prevent foreign matter from getting between the valve and valve bore.

Do not reuse oil seals, gaskets, seal rings, or O-rings during overhaul. Replace these parts as a matter of course. Also do not reuse snap rings or E-clips that are bent or distorted. Replace these parts as well.

Lubricate transfer case parts with Mopar® ATF+4 ATF, Automatic Transmission Fluid, during overhaul and assembly. Use petroleum jelly to prelubricate seals, O-rings, and thrust washers. Petroleum jelly can also be used to hold parts in place during reassembly.

Clean the case in a solvent tank. Flush the case bores and fluid passages thoroughly with solvent. Dry the case and all fluid passages with compressed air. Be sure all solvent is removed from the case and that all fluid passages are clear.

Note. Do not use shop towels or rags to dry the case (or any other transmission component) unless they are made from lint-free materials. Lint will stick to case surfaces and transmission components and circulate throughout the transmission after assembly. A sufficient quantity of lint can block fluid passages and interfere with valve body operation.

1. Mount transfer case on a transmission jack.
2. Secure transfer case to jack with chains.
3. Position transfer case under vehicle.
4. Align transfer case (1) and transmission (3) shafts and install transfer case onto the transmission. see scheme 47
5. Install and tighten transfer case attaching nuts (2) to 35 N.m (26 ft. lbs.) torque.
6. Connect the transfer case vent hose (4).
7. Connect front propeller shaft and install rear propeller shaft. Refer to «INSTALLATION»(ref-306145-S42837456412008120900000). 1 - I.D. TAG 2 - FILL PLUG 3 - DRAIN PLUG
8. For NV140, fill transfer case with correct fluid. Refer to «DESCRIPTION»(ref-306134-S06534103112008120900000). Correct as necessary.
9. Install the transfer case fill plug (1). Tighten the plug to 12 - 15N.m (9-11 ft.lbs.).
10. Install rear crossmember and skid plate, if equipped. Tighten crossmember bolts to 41 N.m (30 ft. lbs.) torque.
11. Remove transmission jack and support stand.
12. Lower vehicle and verify transfer case shift operation.

SPECIFICATIONS

TORQUE SPECIFICATIONS

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

FRONT OUTPUT SHAFT SEAL

The front output shaft seal and wear sleeve cannot be serviced in the vehicle. The transfer case must be disassembled to remove the front output shaft assembly and seal.

Scheme 38

Scheme 39

1. Remove the rear propeller shaft. Refer to «REMOVAL»(ref-306145-S17464238962008120900000).
2. Using Holder C-3281 (1), remove the rear companion flange (2) nut. (Scheme 38) 1 - REAR OUTPUT SHAFT FLANGE 2 - REAR OUTPUT SHAFT
3. Remove the rear output flange (1) from the main shaft (2). If necessary, use a suitable 2 or 3 jaw puller to remove the output shaft flange. (Scheme 39)
4. Remove the rear output seal with a suitable pry tool or a screw mounted in a slide hammer.

1. Install a new rear output seal into the rear cover with Installer C-3972A.
2. Install the rear output flange (1) onto the main shaft (2). see scheme 61 1 - HOLDER C-3281 2 - REAR OUTPUT SHAFT FLANGE
3. Using Holder C-3281 (1), install the rear companion flange (2) nut. Tighten the nut to 122-176 N.m (90-130 ft.lbs.). see scheme 62
4. Install the rear propeller shaft. Refer to «REMOVAL»(ref-306145-S17464238962008120900000).
5. Check the transfer case fluid level. See «STANDARD PROCEDURE»(ref-306220-S01211176292008120900000). Correct as necessary.