Section 1230 (BW44-46 Transfer Case (Service Information) 2500 Hd & 3500 Hd): Disassembly: Disassembly

WARNING: This page is about a different car, the 2016 RAM 3500 HD and 2016 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Shift Motor, Mounting Bolt, Fill & Drain Plugs

GC0151996

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Place the transfer case so that it can be drained of any remaining fluid and remove the fill (4) and drain plugs (1).
Remove the four shift motor mounting bolts (2) and remove the shift motor (3).

Fig 2: Rear Output Shaft Flange Nut
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Remove the rear output shaft flange nut (1), if equipped.

Fig 3: Flange Spacer
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Remove the flange spacer (1), if equipped.

Fig 4: Flange Dust Seal
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Remove the flange dust seal, if equipped.
Using a suitable puller, remove the output flange, if equipped.

Fig 5: Pry Points & Case Half Bolts
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Remove all of the case half bolts (1).
Carefully using a prybar at pry points (2), separate and remove the rear case half.

Fig 6: Retaining Ring
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Remove the retaining ring (1).

Fig 7: Locking Collar
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Remove the locking collar (1).

Fig 8: Main Shaft, Shift Fork, Spring & Sleeve
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Remove the mode shift fork, spring and sleeve (1) from the main shaft (2).

Fig 9: Chain, Front Output Gear, & Mainshaft Gear
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Remove the chain (2), the front out put gear (1) and main shaft gear (3) as an assembly.

Fig 10: Mainshaft & Center Bearing Support Assembly
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NOTE:
There are three alignment tabs and an oil pump hose pass through incorporated into the support that prevent the structure from rotating once installed.
Remove the center bearing support assembly (2) from the mainshaft (1).

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

Fig 12: Magnet
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Remove the magnet (1).

Fig 13: Shift Assembly
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Remove the shift assembly (1).

Fig 14: Mainshaft
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Remove the main shaft.

Fig 15: Shift Rail, Lower Shift Fork & Reduction Hub
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Remove the shift rail (1), lower shift fork (3), and the reduction hub as an assembly.
Separate the lower shift fork (3) from the reduction hub (2).
Separate the lower shift fork (3) from the shift rail (1).

Fig 16: Planetary Carrier & Annulus Gear
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Lift the planetary carrier (1) straight up and out of the annulus gear (2).

Fig 17: Thrust Bearing & Planetary
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NOTE:
Bearing tabs face upward.
Remove the carrier thrust bearing (1) from the center of the planetary (2).

Fig 18: Annulus Gear Retainer
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Remove the annulus gear retainer (1).

Fig 19: Annulus Gear
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Remove the annulus gear (1).

Fig 20: Front Output Shaft & Retaining Ring
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Remove the front output shaft retaining ring (1) from the front output shaft (2).

Fig 21: Front Output Shaft & Front Case Half
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Remove the front output shaft (1) from the front case half (2).

Fig 22: Removing Front Output Shaft Seal & Bearing
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Remove front output shaft seal.
Using (special tool #9622, Installer, Countershaft Plug) (1) and (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 input shaft seal.
Using (special tool #9622, Installer, Countershaft Plug) (1) and (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 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 front output shaft rear bearing (3) from rear case half.