Overhaul (Disassembly)
TRANSFER CASE - NV140 - SERVICE INFORMATIONDISASSEMBLY
1. Remove the bolts (1) holding the damper (2) to the rear case (3).
2. Remove the damper (1) from the rear case (2).
3. Position transfer case on shallow drain pan. Remove drain plug (3) and drain lubricant.
4. Using Holder C-3281 (1), remove the rear output flange (2) nut.
5. 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.
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).
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).
10. Remove mainshaft drive sprocket retaining ring.
11. Remove front output shaft drive sprocket retaining ring (2) from the front output shaft (1).
12. Remove the drive sprockets (1, 2) and the drive chain (3) as one.
13. Remove the mainshaft and differential assembly (1) from the front case (2).
14. Remove the input gear thrust washer (1) from the input gear (2).
15. Remove the screws (1) holding the chain guide rails to the front case (2).
16. Remove the drive chain guide (1) from the transfer case.
17. Remove the differential snap-ring (1).
18. Remove the differential assembly (1) from the mainshaft (2).
19. Remove the mode hub (2) and mode hub retainer from the differential assembly (1).
20. Remove the mode hub retainer (1) from the mode hub (2).
21. Remove the retaining ring (2) from the front output shaft (1).
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.
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.