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Section 1680 (BW44-46 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 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 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 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 (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 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).
    GC0152012Courtesy of CHRYSLER GROUP, LLC
  9. Install the front output shaft (1) into the front housing (2).
    GC0143867Courtesy of CHRYSLER GROUP, LLC
  10. Install the front output shaft retaining ring (1) on the front output shaft (2).
    GC0143866Courtesy of CHRYSLER GROUP, LLC
  11. Install the annulus gear (1).
    GC0143990Courtesy of CHRYSLER GROUP, LLC
  12. Install the annulus gear retainer (1).
    GC0152010Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Bearing tabs face upward.

  13. Install the carrier assembly (2) and thrust bearing (1).
    GC0152008Courtesy of CHRYSLER GROUP, LLC
  14. Install the range shift fork (2), reduction hub and shift rail (1).
    GC0152007Courtesy of CHRYSLER GROUP, LLC
  15. Install main shaft (1).
    GC0143862Courtesy of CHRYSLER GROUP, LLC
  16. Install the shift assembly (1). Be sure the pin is seated in the case.
    GC0143860Courtesy of CHRYSLER GROUP, LLC
  17. Install the magnet (1).
    GC0152006Courtesy of CHRYSLER GROUP, LLC
  18. Install the oil pump assembly (1).
    GC0152005Courtesy 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.

  19. Install the center bearing support assembly (2) onto the main shaft (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.

  20. Install the chain (2), the front out put gear (1) and main shaft gear (3).
    GC0152003Courtesy of CHRYSLER GROUP, LLC
  21. Install the mode shift fork (1) onto the main shaft (2)
    GC0152002Courtesy of CHRYSLER GROUP, LLC
  22. Install the locking collar (1).
    GC0152001Courtesy of CHRYSLER GROUP, LLC
  23. Install the retaining ring (1).
    GC0151997Courtesy of CHRYSLER GROUP, LLC
  24. Clean mating surface of both case halves.
  25. Apply a thin bead of transfer case sealant.
  26. Install rear cover.
  27. Install all of the case half bolts (1) and tighten in a star pattern to 31 N.m (23 ft. lbs.).
    GC0152000Courtesy of CHRYSLER GROUP, LLC
  28. Install the rear output flange, if equipped.
  29. Install the flange dust seal (1), if equipped.
    GC0151999Courtesy of CHRYSLER GROUP, LLC
  30. Install the flange spacer (1), if equipped.
    GC0151998Courtesy of CHRYSLER GROUP, LLC
  31. Install the rear output flange nut (1) and tighten to 241 N.m (178 ft. lbs.), if equipped
  32. Stake the nut to the shaft to prevent the nut from backing off, if equipped.
    GC0151996Courtesy of CHRYSLER GROUP, LLC
  33. Install the fill (4) and drain (1) plugs.
  34. Install the shift motor (3), the four mounting bolts (2) and tighten to 9 N.m (84 in. lbs.).
  35. Install transfer case into vehicle. Refer to INSTALLATION  .
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