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Section 1643 (BW44-47 Transfer Case - (Service Information) - 2500 Hd): Assembly

WARNING: This page is about a different car, the 2017 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
GC0143881Courtesy of CHRYSLER GROUP, LLC
NOTE:

When pressing bearings into the case, be sure to properly support the underside of the case half.

  1. Using (special tool #9598, Installer, Seal) (1) and an Arbor Press, install the front output shaft bearing (2) into the front case half (5).
  2. Using (special tool #9754, Installer, Seal) (3) and an Arbor Press, install the input shaft bearing (4) into the front case half (5).
    GC0143882Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    When pressing bearings into the case, be sure to properly support the underside of the case half.

  3. Using (special tool #9598, Installer, Seal) (1) and an Arbor Press, install the rear output shaft bearing (2) into the front case half (3).
    GC0143883Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    When pressing bearings into the case, be sure to properly support the underside of the case half.

  4. 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).
    GC0143884Courtesy of CHRYSLER GROUP, LLC
  5. Using i (special tool #9754, Installer, Seal) (2) and (special tool #C-4171, Driver Handle, Universal) (1), install input shaft seal (3).
    GC0143885Courtesy of CHRYSLER GROUP, LLC
  6. Using (special tool #10174, Installer, Seal, Rear Output) (1), install the front output shaft seal (2).
    GC0143886Courtesy of CHRYSLER GROUP, LLC
  7. If transfer case is equipped with a flange, and using (special tool #9672, Installer, Seal) (2) with (special tool #C-4171, Driver Handle, Universal) (1), install rear output seal (3).
    GC0152072Courtesy of CHRYSLER GROUP, LLC
  8. If transfer case is equipped with a slip yoke, and using (special tool #9037, Installer, Dust Boot/Seal) (2) with (special tool #C-4171, Driver Handle, Universal) (1), install the rear output seal (3).
    GC0152073Courtesy of CHRYSLER GROUP, LLC
  9. Install the shift shaft seal (1) in the case (2).
    GC0152012Courtesy of CHRYSLER GROUP, LLC
  10. Install the front output shaft (1) into the front housing (2).
    GC0152011Courtesy of CHRYSLER GROUP, LLC
  11. Install the front output shaft snap ring (1) on the front output shaft (2).
    GC0152071Courtesy of CHRYSLER GROUP, LLC
  12. Install the shift fork lever (1).
    GC0152070Courtesy of CHRYSLER GROUP, LLC
  13. Install the manual shift lever (1) in the case through the shift fork lever.
    GC0152069Courtesy of CHRYSLER GROUP, LLC
  14. Tighten the retaining screw (1) to 10 N.m (96 in. lbs).
    GC0152068Courtesy of CHRYSLER GROUP, LLC
  15. Install the detent spring (1) and roller (2) in the shift assembly.
    GC0152067Courtesy of CHRYSLER GROUP, LLC
  16. Install the detent spring (1) in the pocket in the case.
    GC0143866Courtesy of CHRYSLER GROUP, LLC
  17. Install the annulus gear (1).
    GC0143990Courtesy of CHRYSLER GROUP, LLC
  18. Install the annulus gear retainer (1).
    GC0152010Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Bearing tabs face upward.

  19. Install the carrier thrust bearing (1) from the center of the planetary (2).
    GC0152009Courtesy of CHRYSLER GROUP, LLC
  20. Install the planetary carrier (1) into the annulus gear (2).
    GC0152066Courtesy of CHRYSLER GROUP, LLC
  21. With the shifter (1) rotated fully, install the lower shift fork (2), and the reduction hub (3) as an assembly.
    GC0152065Courtesy of CHRYSLER GROUP, LLC
  22. Install the main shaft (1).
    GC0152064Courtesy of CHRYSLER GROUP, LLC
  23. Install the shift shaft (1).
    GC0152063Courtesy of CHRYSLER GROUP, LLC
  24. Install the magnet (1).
    GC0152062Courtesy of CHRYSLER GROUP, LLC
  25. Install the oil pump (1).
    GC0152061Courtesy of CHRYSLER GROUP, LLC
    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.

  26. Install the center bearing support assembly (2) on the mainshaft (1).
    GC0152004Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Chain and gears are patterned and must be installed correctly. Blue links on the chain must be installed facing upward.

  27. Install the chain (2), the front out put gear (1) and main shaft gear (3) as an assembly.
    GC0152003Courtesy of CHRYSLER GROUP, LLC
  28. Install the mode shift fork, spring and sleeve (1) on the main shaft (2).
    GC0152002Courtesy of CHRYSLER GROUP, LLC
  29. Install the locking collar (1).
    GC0152001Courtesy of CHRYSLER GROUP, LLC
  30. Install the retaining ring (1).
    GC0152060Courtesy of CHRYSLER GROUP, LLC
  31. Clean the mating surface of both case halves.
  32. Apply a thin bead of transfer case sealant.
  33. Install the rear cover.
  34. Install all of the case half bolts and tighten in a star pattern to 31 N.m (23 ft. lbs.).
    GC0152075Courtesy of CHRYSLER GROUP, LLC
  35. Install the position switch (1) and tighten to 27 N.m (20 ft. lbs.).
    GC0152000Courtesy of CHRYSLER GROUP, LLC
  36. Install the output flange, if equipped.
  37. Install the flange dust seal, if equipped.
    GC0151999Courtesy of CHRYSLER GROUP, LLC
  38. Install the flange spacer (1), if equipped.
    GC0151998Courtesy of CHRYSLER GROUP, LLC
  39. Install the rear output flange nut (1) and tighten to 241 N.m (178 ft. lbs.), if equipped.
  40. Install the transfer case into vehicle. Refer to INSTALLATION .
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