Service Information: Disassembly

Fig 1: MS 140 Rear View

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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: Rear Output Flange Nut

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   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: Rear Output Flange

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   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: Front Output Flange Nut

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   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: Remove Front Output Shaft Flange

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   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: Transfer Case Cover Bolts

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   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: Transfer Case Cover

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   1 - TRANSFER CASE COVER

   2 - TRANSFER CASE

9. Remove the transfer case cover (1) from the transfer case (2). See Fig 7.
   Fig 8: Rear Output Shaft Bearing Snap-Ring

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   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: Output Shaft

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    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: Snap-Ring

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    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: Planetary Gear System

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    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: Rear Housing Bolts

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    1 - BOLTS

    2 - REAR HOUSING

16. Remove the bolts (1) holding the rear housing (2) to the front housing. See Fig 12.
    Fig 13: Rear Housing

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    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: Front Output Shaft

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    1 - FRONT OUTPUT SHAFT

    2 - FRONT HOUSING

18. Remove the front output shaft (1) from the front housing (2). See Fig 14.
    Fig 15: Intermediate Gear

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    1 - INTERMEDIATE GEAR

    2 - FRONT HOUSING

19. Remove the intermediate gear (1) from the front housing (2). See Fig 15.
    Fig 16: Remove Input Shaft And Hollow Gear Assembly

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    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: Input Gear Snap-Ring

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    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: Input Gear Thrust Washer

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    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: Remove Hollow Gear

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    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

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    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 And Remove Race

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    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: Remove Front Output Shaft Front Bearing

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    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: Remove Front Output Shaft Rear Bearing

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    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: Remove Hollow Gear Front Bearing

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    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: Remove Hollow Gear Rear Bearing

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    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: Remove Intermediate Gear Bearing

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    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.