Section 306 (BW44-44 Transfer Case (Service Information) 1500): Assembly: Assembly

WARNING: This page is about a different car, the 2013 RAM 1500. However, it is still accessible from the selected car via links, so may be relevant.

Check the clearance for the new clutch pack, and select a new spacer if necessary. Refer to ADJUSTMENTS .

Fig 1: Pressing Bearings Into Case
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NOTE:
When pressing bearings into case, be sure to properly support the underside of the case half.
Using (special tool #9598, Installer, Seal) (1) and an Arbor Press, install the front output shaft bearing (2) into the front case half (5).
Using (special tool #9754, Installer, Seal) (3) and an Arbor Press, install the input shaft bearing (4) into the front case half (5).

Fig 2: Installing Rear Output Shaft Bearing
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NOTE:
When pressing bearings into case, be sure to properly support the underside of the case half.
Using (special tool #9598, Installer, Seal) (1) and an Arbor Press, install the rear output shaft bearing (2) into the front case half (3).

Fig 3: Installing Front Output Shaft Bearing
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NOTE:
When pressing bearings into case, be sure to properly support the underside of the case half.
Using (special tool #9598, Installer, Seal) (1) and an Arbor Press, install the front output shaft rear support bearing (2) into the front case half (3).

Fig 4: Installing Input Shaft Seal
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Using (special tool #9754, Installer, Seal) (2) and (special tool #C-4171, Driver Handle, Universal) (1), install input shaft seal (3).

Fig 5: Installing Front Output Shaft Seal
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Using (special tool #10174, Installer, Seal, Rear Output) (1), install front output shaft seal (2).

Fig 6: Installing Rear Output Seal
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Using (special tool #9672, Installer, Seal) (2) with (special tool #C-4171, Driver Handle, Universal) (1), install rear output seal (3).

Fig 7: Clutch Coil
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Install clutch coil (1) in rear housing.

Fig 8: Convoluted Cover
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Install the coil mounting nuts (2) and tighten to 9 N.m (84 in. lbs.).
Install convoluted cover (1) on coil wire.

Fig 9: Front Output Shaft
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Install the front output shaft (1) into the front housing (2).

Fig 10: Front Output Shaft Snap Ring
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Install the front output shaft snap ring (1) on the front output shaft (2).

Fig 11: Annulus Gear
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Install the annulus gear (1).

Fig 12: Annulus Gear Retainer
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Install the annulus gear retainer (1).

Fig 13: Carrier Assembly & Thrust Bearing
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Install the carrier assembly (1) and thrust bearing (2).

Fig 14: Shift Fork & Reduction Hub
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Install the shift rail (2), shift fork (1), and reduction hub.

Fig 15: Main Shaft
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Install main shaft (1).

Fig 16: Shift Assembly
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Install shift assembly (1). Be sure pin is seated in case.

Fig 17: Oil Pump Assembly
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Install oil pump assembly (1).

Fig 18: Magnet
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Install magnet (1).

Fig 19: Lower Thrust Bearing Assembly
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Install lower thrust bearing assembly. Bearing consists of a lower washer (3), bearing (2), and an upper washer (1).

Fig 20: Chain, Front Output Sprocket & Main Shaft Sprocket
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NOTE:
Chain and gears are patterned and must be install correctly. Blue links on the chain must be install facing upward.
Install the chain (2), front output sprocket (1) and main shaft sprocket (3).

Fig 21: Clutch Assembly
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Install the clutch assembly (1) on the input shaft (2).

Fig 22: Snap Ring
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Install the snap ring (1) on the input shaft (2).

Fig 23: Wave Spring
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Install the wave spring (1) on the input shaft.

Fig 24: Ball Bearings & Apply Cam
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Install the apply cam (2).
Install the ball bearings (1) on the apply cam (2).

Fig 25: Clutch Rotor
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Install the clutch rotor (1).

Fig 26: Bearing
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Install bearing (1).

Fig 27: Spacer
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Install spacer (1).

Fig 28: Retaining Ring
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Install retaining ring (1).

Fig 29: Case Half Bolts
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Clean mating surface of both case halves.
Apply a thin bead of transfer case sealant.
Install rear cover.
Install all of the case half bolts (2) and tighten in a star pattern to 31 N.m (23 ft. lbs.).

Fig 30: Shift Motor Electrical Connector
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Carefully install the clutch coil wire into connector. Install the center of the electrical connector (1).

Fig 31: Shift Motor Mounting Bolts
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Install the shift motor mounting bolts and tighten to 9 N.m (84 in. lbs.).
Install transfer case into vehicle. Refer to INSTALLATION .