Section 1680 (BW44-46 Transfer Case - (Service Information) - 2500 Hd): Disassembly

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.

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).

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Remove the rear output shaft flange nut (1), if equipped.

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Remove the flange spacer (1), if equipped.

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Remove the flange dust seal, if equipped.
Using a suitable puller, remove the output flange, if equipped.

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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.

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Remove the retaining ring (1).

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Remove the locking collar (1).

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Remove the mode shift fork, spring and sleeve (1) from the main shaft (2).

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Remove the chain (2), the front out put gear (1) and main shaft gear (3) as an 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).

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Remove the oil pump (1).

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Remove the magnet (1).

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Remove the shift assembly (1).

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Remove the main shaft.

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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).

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Lift the planetary carrier (1) straight up and out of the annulus gear (2).

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

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Remove the annulus gear retainer (1).

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Remove the annulus gear (1).

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Remove the front output shaft retaining ring (1) from the front output shaft (2).

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Remove the front output shaft (1) from the front case half (2).

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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).

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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).

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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).

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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.