MP143 Transfer Case - Service Information: Other Dodge Nitro I

CLEANING-TRANSFER CASE MP143

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.

TRANSFER CASE - MP143

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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 8245 (2), and Handle C-4171 (1). 1 - FRONT HOUSING 2 - FRONT OUTPUT SHAFT
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. 1 - FRONT OUTPUT SHAFT 2 - RETAINING RING
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. 1 - DRIVE CHAIN GUIDE
11. Install the both drive chain guide rails (1) onto the transfer case. 1 - SCREWS 2 - FRONT CASE
12. Install the screws (1) to hold the both chain guide rails to the front case (2). Tighten the screws to 5-8 N.m (44-71 in.lbs.). 1 - MODE HUB 2 - MAINSHAFT
13. Install the mode hub (1) onto the mainshaft (2). 1 - MODE HUB SNAP RING 2 - MODE HUB 3 - MAINSHAFT
14. Install the mode hub snap ring (1) onto the mainshaft (3). 1 - MAINSHAFT 2 - MODE SLEEVE
15. Install the mode sleeve (2) onto the mainshaft (1). 1 - MODE FORK 2 - MODE FORK RETURN SPRING
16. Install the mode fork return spring (2) onto the mode fork (1). 1 - MODE FORK ASSEMBLY 2 - MAINSHAFT
17. Install the mode fork assembly (1) onto the mainshaft (2). 1 - FRONT DRIVE SPROCKET 2 - MAINSHAFT DRIVE SPROCKET 3 - DRIVE CHAIN
18. Install the drive sprockets (1, 2) and drive chain (3) and shift lever as one. 1 - FRONT OUTPUT SHAFT 2 - RETAINING RING
19. Install the front output shaft (1) drive sprocket retaining ring (2). 1 - RETAINING RING
20. Install the mainshaft retaining ring (1). 1 - REAR HOUSING 2 - FRONT HOUSING
21. Install the transfer case magnet into the magnet pocket.
22. 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.
23. Install the rear case (1) onto the front case (2). 1 - Item_1 2 - Item _2 NOTE: Tighten the bolts at the alignment dowel locations first.
24. Apply MOPAR® lock and seal onto the transfer case bolts and install the transfer case bolts. Tighten the bolts to 27 N.m (20 ft.lbs.). 1 - SHIFT MOTOR O-RING 2 - SHIFT MOTOR 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. 1 - SHIFT MOTOR
26. Install the shift motor (1) into the transfer case.
27. Apply MOPAR® 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 N.m (9 ft.lbs.). 1 - Item_1 2 - Item _2
28. Install a new rear output seal into the rear case with Installer C-3972A.
29. Install the dampener onto the transfer case. 1 - Item_1 2 - Item _2
30. Apply MOPAR® lock and seal onto the dampener bolts and install the dampener bolts into the transfer case. Tighten the transfer case dampener bolts to 27 N.m (20 ft.lbs.). 1 - REAR OUTPUT SHAFT FLANGE 2 - MAINSHAFT
31. Install the rear output flange (1) onto the output shaft (2). 1 - HOLDER C-3281 2 - REAR OUTPUT SHAFT FLANGE
32. Using Holder C-3281 (1), install the rear output shaft flange (2) nut. Tighten the nut to 122-176 N.m (90-130 ft.lbs.). 1 - FILL PLUG 4 - SHIFT MOTOR 2 - DRAIN PLUG 5 - DAMPENER 3 - ID TAG 6 - REAR OUTPUT SHAFT FLANGE
33. Install and tighten drain plug (2) to 12-15 N.m (9-11 ft. lbs.).

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.