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Transfer Case - Ms140

WARNING: This page is about a different car, the 2008 Dodge Magnum, 2008 Dodge Charger, and 2008 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: MS 140 Rear View
GC0012862Courtesy of CHRYSLER LLC
1 - TRANSFER CASE
2 - FILL PLUG
3 - IDENTIFICATION LABEL
4 - INSPECTION PLUG
5 - DRAIN PLUG
  1. Place the transfer case so that it can be drained of any remaining fluid and remove the drain plug (5). See Fig 1.
    Fig 2: Removing Rear Output Flange Nut
    GC0012868Courtesy of CHRYSLER LLC
    1 - HOLDER 6958
    2 - REAR OUTPUT SHAFT FLANGE
  2. Install Holder 6958 (1) onto the rear output flange (2). See Fig 2.
  3. Remove the output shaft nut.
    Fig 3: Removing Rear Output Flange
    GC0012869Courtesy of CHRYSLER LLC
    1 - TRANSFER CASE
    2 - REAR OUTPUT SHAFT FLANGE
  4. Remove the rear output shaft flange (2) from the output shaft. If the flange is difficult to remove, use a suitable 2 or 3 jaw puller to remove the flange. See Fig 3.
    Fig 4: Removing Front Output Flange Nut
    GC0012870Courtesy of CHRYSLER LLC
    1 - HOLDER 6958
    2 - FRONT OUTPUT SHAFT FLANGE
  5. Install Holder 6958 (1) onto the front output flange (2). See Fig 4.
  6. Remove the output shaft nut.
    Fig 5: Removing Front Output Shaft Flange
    GC0012872Courtesy of CHRYSLER LLC
    1 - PULLER
    2 - FLANGE
  7. Remove the front output shaft flange (2) from the output shaft. If the flange (2) is difficult to remove, use a suitable 2 or 3 jaw puller (1) to remove the flange. See Fig 5.
    Fig 6: Removing Transfer Case Cover Bolts
    GC0012871Courtesy of CHRYSLER LLC
    1 - OUTPUT SHAFT
    2 - TRANSFER CASE COVER
    3 - BOLTS
  8. Remove the bolts (3) holding the transfer case rear cover (2) to the transfer case. See Fig 6.
    Fig 7: Removing Transfer Case Cover
    GC0012873Courtesy of CHRYSLER LLC
    1 - TRANSFER CASE COVER
    2 - TRANSFER CASE
  9. Remove the transfer case cover (1) from the transfer case (2). See Fig 7.
    Fig 8: Removing Rear Output Shaft Bearing Snap-Ring
    GC0012892Courtesy of CHRYSLER LLC
    1 - SNAP-RING
    2 - TRANSFER CASE COVER
  10. Remove the rear output shaft seal from the transfer case cover with a suitable pry tool.
  11. Remove the rear output shaft bearing snap-ring (1) from the transfer case cover (2). See Fig 8.
  12. Remove the output shaft bearing from the cover using a suitable drift tool.
    Fig 9: Removing Output Shaft
    GC0012875Courtesy of CHRYSLER LLC
    1 - OUTPUT SHAFT
    2 - PLANETARY GEAR SYSTEM
    3 - TRANSFER CASE REAR HOUSING
  13. Remove the output shaft (1) from the planetary gear system (2). See Fig 9.
    Fig 10: Removing Snap-Ring from Input Shaft
    GC0012874Courtesy of CHRYSLER LLC
    1 - INPUT SHAFT
    2 - SNAP-RING
    3 - PLANETARY GEAR SYSTEM
  14. Remove the snap-ring (2) holding the input shaft (1) to the planetary gear system (3). See Fig 10.
    Fig 11: Removing Planetary Gear System
    GC0012876Courtesy of CHRYSLER LLC
    1 - PLANETARY GEAR SYSTEM
    2 - REAR HOUSING
  15. Remove the planetary gear system (1) from the transfer case rear housing (2). See Fig 11.
    Fig 12: Removing Rear Housing Bolts
    GC0012878Courtesy of CHRYSLER LLC
    1 - BOLTS
    2 - REAR HOUSING
  16. Remove the bolts (1) holding the rear housing (2) to the front housing. See Fig 12.
    Fig 13: Removing Rear Housing
    GC0012877Courtesy of CHRYSLER LLC
    1 - REAR HOUSING
    2 - FRONT HOUSING
  17. Loosen the rear housing (1) from the front housing (2) by prying the sections apart at the provided slots. Remove the rear housing (1) from the front housing (2). See Fig 13.
    Fig 14: Removing Front Output Shaft
    GC0012879Courtesy of CHRYSLER LLC
    1 - FRONT OUTPUT SHAFT
    2 - FRONT HOUSING
  18. Remove the front output shaft (1) from the front housing (2). See Fig 14.
    Fig 15: Removing Intermediate Gear
    GC0012880Courtesy of CHRYSLER LLC
    1 - INTERMEDIATE GEAR
    2 - FRONT HOUSING
  19. Remove the intermediate gear (1) from the front housing (2). See Fig 15.
    Fig 16: Removing Input Shaft & Hollow Gear Assembly
    GC0012881Courtesy of CHRYSLER LLC
    1 - INPUT GEAR AND HOLLOW SHAFT ASSEMBLY
    2 - FRONT HOUSING
  20. Remove the input gear and hollow shaft assembly (1) from the front housing (2). See Fig 16.
    Fig 17: Removing Input Gear Snap-Ring
    GC0012882Courtesy of CHRYSLER LLC
    1 - INPUT SHAFT
    2 - SNAP-RING
    3 - HOLLOW SHAFT
  21. Remove the snap-ring (2) holding the input shaft (1) in the hollow shaft (3). See Fig 17.
    Fig 18: Removing Input Gear Thrust Washer
    GC0012883Courtesy of CHRYSLER LLC
    1 - INPUT SHAFT
    2 - THRUST WASHER
    3 - HOLLOW SHAFT
  22. Remove the input gear thrust washer (2) from the input shaft (1) and hollow shaft (3). See Fig 18.
    Fig 19: Removing Hollow Gear
    GC0012884Courtesy of CHRYSLER LLC
    1 - INPUT SHAFT
    2 - HOLLOW SHAFT
  23. Remove the hollow shaft (2) from the input shaft (1). See Fig 19.
    CAUTION: Inspect the needle bearing located inside the hollow shaft. If the needle bearing is within 1 mm (0.040 in.) of the edge of the hollow shaft, the hollow shaft must be replaced. DO NOT attempt to drive the bearing back into the hollow shaft.
    Fig 20: Install L-4518 Jaws
    GC0012885Courtesy of CHRYSLER LLC
    1 - REAR HOUSING
    2 - L-4518 JAWS
  24. Install the jaws from Remover L-4518 (2) into the intermediate gear rear bearing race in the rear housing (1). See Fig 20.
    Fig 21: Install L-4518 Cup & Remove Race
    GC0012886Courtesy of CHRYSLER LLC
    1 - REAR HOUSING
    2 - L-4518 CUP
  25. Install the cup from Remover L-4518 (2) onto the jaws. Install the bearing, washer, and nut onto the threaded shaft and remove the bearing race. See Fig 21.
  26. Repeat step  24 and step  25 for the other blind bearing races in the front and rear housings.
  27. Drive out the input gear and front output shaft seals with a suitable drift.
  28. Drive out the front hollow shaft and front output shaft front bearing races with a suitable brass drift.
    Fig 22: Removing Front Output Shaft Front Bearing
    GC0012887Courtesy of CHRYSLER LLC
    1 - PRESS C-293-PA
    2 - FRONT OUTPUT SHAFT
    3 - ADAPTERS C-293-52
  29. Remove the front output shaft (2) front bearing with Press C-293-PA (1) and Adapters C-293-52 (3). See Fig 22.
    Fig 23: Removing Front Output Shaft Rear Bearing
    GC0012888Courtesy of CHRYSLER LLC
    1 - PRESS C-293-PA
    2 - PLUG 8513A
    3 - ADAPTERS C-293-52
    4 - FRONT OUTPUT SHAFT
  30. Remove the front output shaft (4) rear bearing with Press C-293-PA (1), Plug 8513A (2), and Adapters C-293-52 (3). See Fig 23.
    Fig 24: Removing Hollow Gear Front Bearing
    GC0012889Courtesy of CHRYSLER LLC
    1 - PRESS C-293-PA
    2 - 9678
    3 - HOLLOW SHAFT
    4 - ADAPTERS C-293-48
  31. Remove the front hollow shaft (3) bearing with Press C-293-PA (1), Plug 9678 (2), and Adapters C-293-48 (4). See Fig 24.
    Fig 25: Removing Hollow Gear Rear Bearing
    GC0012890Courtesy of CHRYSLER LLC
    1 - PRESS C-293-PA
    2 - SP3289 PLUG
    3 - ADAPTERS C-293-48
    4 - HOLLOW SHAFT
  32. Remove the rear hollow shaft (4) bearing with Press C-293-PA (1), Plug SP3289 (2), and Adapters C-293-48 (3). See Fig 25.
    Fig 26: Removing Intermediate Gear Bearing
    GC0012891Courtesy of CHRYSLER LLC
    1 - PRESS C-293-PA
    2 - 8513A PLUG
    3 - ADAPTERS C-293-40
    4 - INTERMEDIATE GEAR
  33. Remove the front and rear intermediate gear (4) bearings with Press C-293-PA (1), Plug 8513A (2), and Adapters C-293-40 (3). See Fig 26.
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