Section 14 (BW44-40 Transfer Case (Service Information)): Assembly

WARNING: This page is about a different variant/trim than selected.

GC0095894

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Check the clearance for the new clutch pack, and select a new spacer if necessary. Refer to ADJUSTMENTS .
Position the rear transfer case half (3) on a suitable arbor press, and position the (special tool #8835-3, Receiver, Bushing) Bushing Receiver (1) to support the rear transfer case half (3) from below in the area of the output shaft bearing.
Use the (special tool #8441-2, Cup, Receiver) Receiver Cup (2) and an arbor press to install the output shaft bearing into the rear transfer case half (3).

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Use the (special tool #D-156, Installer, Bearing) Bearing Installer (1) and an arbor press to install the input shaft bearing (2) into the rear transfer case half (3).

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Install the snubbers (3), the snubber bolts (1, 2) and tighten to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
Install the oil baffle (5), the oil baffle bolts (4) and tighten to the proper specification. Refer to TECHNICAL SPECIFICATIONS .

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Route the wires through the rear transfer case half (2) and install the clutch coil (1) into the rear transfer case half (2).

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Install the clutch coil nuts (1) and tighten to the proper specification. Refer to TECHNICAL SPECIFICATIONS .

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Install clutch coil wire terminal ends into the clutch coil wire harness connector (2), engage the terminal ends in the tabs, then install the cover (1).
NOTE:
If the original convoluted sheath is damaged, install new convoluted sheath
Install the convoluted sheath and install new tie straps to secure it in position.

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Install the wire retainer (1) on the back of the clutch coil wire harness connector (2).

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Position the front transfer case half (1) on an arbor press, and position (special tool #8149, Installer, Seal) Seal Installer (2) to support the input shaft seal flange from below.

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Use (special tool #8153, Installer, Bearing Cup) Bearing Installer (1) and an arbor press to install the input shaft bearing (2) into the front transfer case half.

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Use (special tool #10174, Installer, Seal, Rear Output) Rear Output Seal Installer to install the output shaft seal into the rear transfer case half (2).

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Use (special tool #10173, Installer, Input Shaft Seal) Input Shaft Seal Installer (1) to install the front input shaft seal into the front transfer case half (2).
Use (special tool #10174, Installer, Seal, Rear Output) Rear Output Seal Installer to install the front output shaft seal into the front transfer case half (2).

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Use the (special tool #D-156, Installer, Bearing) Bearing Installer (1) and an arbor press to install the output shaft bearing (2) into the front case half.

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Install the transfer case magnet (1).

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Position the oil pump assembly (1) onto the input shaft (2).

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Slide the oil pump (3) down until it fully engages the splines (2) on the input shaft (1).
Install the bottom spacer (4), the bearing (5), and top spacer (6) onto the input shaft (1).

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Install the input shaft assembly (1) into the front transfer case half (2).

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NOTE:
The output shaft sprocket is pressed onto the output shaft.

NOTE:
If the snap ring (1) is temporarily installed too close to the top of the output shaft, it might not be possible to install it into the bottom groove on the output shaft after the output shaft sprocket is pressed onto the output shaft.
Temporarily install the snap ring (1) approximately 3 mm (0.12 in.) above the groove (3) on the output shaft.
Install the output shaft sprocket, the drive chain and the drive sprocket as an assembly.

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NOTE:
When the output shaft sprocket (2) is at the correct height, the top groove (1) on the output shaft will be visible.
Use the (special tool #8835-3, Receiver, Bushing) Bushing Receiver and a suitable arbor press to install the output shaft sprocket (2) onto the output shaft. Press the sprocket until the top groove (1) on the output shaft is visible.

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Press the output shaft upward with the output shaft flange, then install the snap ring (1) into the groove (3) on the output shaft.

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Install the thrust washer (1) onto the input shaft (2).

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Install a NEW clutch assembly (1) onto the input shaft (2).

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Install the snap ring (1) onto the input shaft (2).

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Install the wave spring (1) onto the input shaft.

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Install the apply cam (2), and the ball bearings (1).

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Install the clutch rotor (1) onto the input shaft.

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Install the bearing (1) onto the input shaft.

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Install the spacer (1).

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Apply a bead of Loctite® 598 HB to the front transfer case half sealing surface.
Install the rear transfer case half (1), rear transfer case half bolts and tighten to the proper specification. Refer to TECHNICAL SPECIFICATIONS .

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Install the rear output flange (1).

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Install a new outer rear output shaft seal (1).

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Install the rear output flange washer (1).

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Install the rear output flange nut.
Install (special tool #6958, Wrench, Spanner) (1) onto the rear output flange (2). Tighten the rear output flange nut to the proper specification
Refer to TECHNICAL SPECIFICATIONS .