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

WARNING: This page is about a different variant/trim than selected.
GC0095875Courtesy of CHRYSLER GROUP, LLC
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.

  1. Temporarily install the snap ring (1) approximately 3 mm (0.12 in.) above the groove (3) on the output shaft.
  2. Install the output shaft sprocket, the drive chain and the drive sprocket as an assembly.
    GC0095901Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    When the output shaft sprocket (2) is at the correct height, the top groove (1) on the output shaft will be visible.

  3. Use the (special tool #8835-3, Receiver, Bushing) Bushing Receiver and an 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.
    GC0095875Courtesy of CHRYSLER GROUP, LLC
  4. Press the output shaft upward with the output shaft flange, then install the snap ring (1) into the groove (3) on the output shaft.
    GC0095874Courtesy of CHRYSLER GROUP, LLC
  5. Install the thrust washer (1) onto the input shaft (2).
    NOTE:

    If installing a new clutch pack, check the clutch pack clearance, and select a new spacer if necessary. Refer to ADJUSTMENTS .

    GC0095873Courtesy of CHRYSLER GROUP, LLC
  6. Install the clutch assembly (1) onto the input shaft (2).
    GC0095872Courtesy of CHRYSLER GROUP, LLC
  7. Install the snap ring (1) onto the input shaft (2).
    GC0095871Courtesy of CHRYSLER GROUP, LLC
  8. Install the wave spring (1) onto the input shaft.
    GC0095870Courtesy of CHRYSLER GROUP, LLC
  9. Install the apply cam (2), and the ball bearings (1).
    GC0095869Courtesy of CHRYSLER GROUP, LLC
  10. Install the clutch rotor (1) onto the input shaft.
    GC0095868Courtesy of CHRYSLER GROUP, LLC
  11. Install the bearing (1) onto the input shaft.
    GC0095867Courtesy of CHRYSLER GROUP, LLC
  12. Install the spacer (1).
    GC0095866Courtesy of CHRYSLER GROUP, LLC
  13. Apply a bead of Loctite® 598 HB to the front case half sealing surface.
  14. Install the rear transfer case half (1) and tighten the rear transfer case bolts to the proper specification. Refer to TECHNICAL SPECIFICATIONS .
    GC0095865Courtesy of CHRYSLER GROUP, LLC
  15. Install the rear output flange (1).
    GC0095864Courtesy of CHRYSLER GROUP, LLC
  16. Install a new outer rear output shaft seal (1).
    GC0095863Courtesy of CHRYSLER GROUP, LLC
  17. Install the rear output flange washer (1).
    GC0095862Courtesy of CHRYSLER GROUP, LLC
  18. Install the rear output flange nut.
  19. Install (special tool #6958, Wrench, Spanner) Spanner Wrench (1) onto the rear output flange (2). Tighten the rear output flange nut to the proper specification

    Refer to TECHNICAL SPECIFICATIONS .

  20. Install the transfer case. Refer to INSTALLATION .
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