Section 1154 (BW44-45 Transfer Case (Service Information) 1500): Disassembly: Disassembly

WARNING: This page is about a different car, the 2016 RAM 1500. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Fill & Drain Plugs

GC0143830

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Place the transfer case so that it can be drained of any remaining fluid and remove the fill (2) and drain plugs (1).

Fig 2: Removing Shift Motor Connector Primary Lock
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Remove the primary lock (1) at the shift motor connector. Carefully disengage the coil wire and remove from the connector.

Fig 3: Shift Motor Mounting Bolts
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Remove the shift motor mounting bolts (1&2).

Fig 4: Pry Points & Case Half Bolts
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Remove all of the case half bolts (2).
Carefully, using a prybar at pry points (1), separate and remove the rear case half.

Fig 5: Retaining Ring
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Remove the retaining ring (1).

Fig 6: Lock-Up Rotor
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Remove the lock-up rotor (1).

Fig 7: Mode Shift Fork & Lock-Up Assembly
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Remove the mode shift fork (1), spring and the lock-up assembly (2).

Fig 8: Main Shaft Sprocket, Output Sprocket & Chain
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Remove the chain (2), front output sprocket (1) and main shaft sprocket (3).

Fig 9: Main Shaft & Lower Thrust Washer
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Remove the lower thrust washer (1) from the main shaft (2).

Fig 10: Removing Magnet
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Remove the magnet (1).

Fig 11: Oil Pump Assembly
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Remove the oil pump assembly (1).

Fig 12: Shift Assembly
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Remove the shift assembly (1).

Fig 13: Main Shaft
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Remove the main shaft (1).

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

Fig 15: Carrier Assembly & Thrust Bearing
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Remove the planetary carrier assembly (1) and thrust bearing (2).

Fig 16: Removing Annulus Gear Retainer
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Remove the annulus gear retainer (1).

Fig 17: Removing Annulus Gear
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Remove the annulus gear (1).

Fig 18: Installing Front Output Shaft Snap Ring
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Remove the front output shaft retaining ring (1) from the front output shaft (2).

Fig 19: Front Output Shaft & Housing
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Remove the front output shaft (1) from the front housing (2).

Fig 20: Removing Convoluted Cover From Coil Wire
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Remove the convoluted cover (1) from the coil wire.
Remove the coil mounting nuts (2).

Fig 21: Removing Lock-Up Coil From Rear Housing
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Remove the lock-up coil (1) from the rear housing.

Fig 22: Removing Front Output Shaft Seal & Bearing
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Remove the front output shaft seal.
Using remover (special tool #9622, Installer, Countershaft Plug) (1) and drive handle (special tool #C-4171, Driver Handle, Universal) (2), remove the front output shaft bearing from the case half (3).

Fig 23: Removing Input Shaft Seal & Bearing
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Remove the input shaft seal.
Using remover (special tool #9622, Installer, Countershaft Plug) (1) and drive handle (special tool #C-4171, Driver Handle, Universal) (2), remove the input shaft bearing from the case half (3).

Fig 24: Removing Rear Output Shaft Seal & Bearing
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Remove the rear output shaft seal.
Using (special tool #5066, Installer, Bushing) and (special tool #C-4171, Driver Handle, Universal) (1), remove the input shaft bearing from the case half (2).

Fig 25: Removing Front Output Shaft Rear Bearing
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Secure the rear case half.
Using (special tool #7794-A, Remover, Seal) (2) and (special tool #C-637, Slide Hammer, Universal) (1), remove the front output shaft rear bearing (3) from the rear case half.