Section 6 (Transfer Case BW 44-40 (Service Information)): Chain: Removal: Removal

Fig 1: Transfer Case And Drain Plug

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1. Remove the transfer case from the vehicle. See Transmission and Transfer Case/Transfer Case - Removal .
   NOTE: The vent hole is near the input shaft hub. If the unit is set on the mounting surface, oil will drain out through the vent.
2. Place the transfer case so that it can be drained of any remaining fluid and remove the drain plug (2).
   Fig 2: Holder 6958 And Rear Output Flange

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3. Install Holder 6958 (1) onto the rear output flange (2).
4. Remove the rear output flange nut.
   Fig 3: Rear Output Flange Washer

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5. Remove the rear output flange washer (1)
   Fig 4: Outer Rear Output Shaft Seal

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6. Remove the outer rear output shaft seal (1)
   Fig 5: Rear Output Flange

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7. Remove the rear output flange (1)
   Fig 6: Transfer Case Rear Cover

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8. Remove the case half bolts.
   NOTE: The clutch rotor might remain in the rear case half during removal.
9. Remove the rear cover (1)
   Fig 7: Spacer

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10. Remove the spacer (1)
    Fig 8: Input Shaft Bearing

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11. Remove the bearing (1) from the input shaft.
    Fig 9: Clutch Rotor

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12. Remove the clutch rotor (1) from the input shaft.
    Fig 10: Ball Bearings And Apply Cam

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13. Remove the ball bearings (1) from the apply cam (2).
14. Remove the apply cam (2).
    Fig 11: Input Shaft Wave Spring

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15. Remove the wave spring (1) from the input shaft.
    Fig 12: Snap Ring And Input Shaft

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16. Remove the snap ring (1) from the input shaft (2).
    Fig 13: Clutch Assembly And Input Shaft

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17. Remove the clutch assembly (1) from the input shaft (2).
    Fig 14: Thrust Washer And Input Shaft

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18. Remove the thrust washer (1) from the input shaft (2).
    Fig 15: Locating Snap Ring

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    NOTE: The output shaft sprocket is pressed onto the output shaft.
19. Release the Snap Ring (1) from the Output Shaft and move it away from the Groove (3), toward the Output Shaft Sprocket (2).
    Fig 16: Brace Plate 10176 And Input Shaft Sprocket

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20. Slide the 10176 Brace Plate (1) in between the case and the input shaft sprocket (2).
    Fig 17: Puller Plate 10176 And Output Shaft Flange

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21. Align the holes on the 10176 Puller Plate (1) with the bolt holes in the output shaft flange (2), then install the 10176 Puller Plate (1) onto the output shaft flange (2).
    Fig 18: Base 10176

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22. Install the 10176 Base (1) onto the puller plate.
    Fig 19: Bearing 10176

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    NOTE: Install the 10176 Bearing (1) so that the bearing flange is facing up.
23. Install the 10176 Bearing (1).
    Fig 20: Nut 10176

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24. Install the 10176 Nut (1).
    Fig 21: Output Shaft

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25. Tighten the nut until the Output Shaft (1) is pulled free of the output shaft sprocket.
26. Remove the Output Shaft Sprocket, the Drive Chain, and the Drive Sprocket as an assembly.