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

WARNING: This page is about a different variant/trim than selected.
GC0095857Courtesy of CHRYSLER GROUP, LLC
  1. Remove the transfer case from the vehicle. Refer to REMOVAL .
    NOTE:

    The vent hole is near the input shaft hub. If the unit is set on the mounting surface, oil will drain out through the vent.

  2. Remove the drain plug (2) and drain the remaining fluid.
    GC0095862Courtesy of CHRYSLER GROUP, LLC
  3. Install (special tool #6958, Wrench, Spanner) Spanner Wrench (1) onto the rear output flange (2).
  4. Remove the rear output flange nut.
    GC0095863Courtesy of CHRYSLER GROUP, LLC
  5. Remove the rear output flange washer (1).
    GC0095864Courtesy of CHRYSLER GROUP, LLC
  6. Remove the outer rear output shaft seal (1).
    GC0095865Courtesy of CHRYSLER GROUP, LLC
  7. Remove the rear output flange (1).
    GC0095866Courtesy of CHRYSLER GROUP, LLC
  8. Remove the transfer case half bolts.
    NOTE:

    The clutch rotor might remain in the rear transfer case half during removal.

  9. Remove the rear transfer case half (1).
    GC0095867Courtesy of CHRYSLER GROUP, LLC
  10. Remove the spacer (1).
    GC0095868Courtesy of CHRYSLER GROUP, LLC
  11. Remove the bearing (1) from the input shaft.
    GC0095869Courtesy of CHRYSLER GROUP, LLC
  12. Remove the clutch rotor (1) from the input shaft.
    GC0095870Courtesy of CHRYSLER GROUP, LLC
  13. Remove the ball bearings (1) from the apply cam (2).
  14. Remove the apply cam (2).
    GC0095871Courtesy of CHRYSLER GROUP, LLC
  15. Remove the wave spring (1) from the input shaft.
    GC0095872Courtesy of CHRYSLER GROUP, LLC
  16. Remove the snap ring (1) from the input shaft (2).
    GC0095873Courtesy of CHRYSLER GROUP, LLC
  17. Remove the clutch assembly (1) from the input shaft (2).
    GC0095874Courtesy of CHRYSLER GROUP, LLC
  18. Remove the thrust washer (1) from the input shaft (2).
    GC0095875Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The output shaft sprocket is pressed onto the output shaft.

  19. Release the snap ring (1) from the output shaft and move it away from the groove (3), toward the output shaft sprocket (2).
    GC0095876Courtesy of CHRYSLER GROUP, LLC
  20. Slide the (special tool #10176, Remover, Front Drive Sprocket) Front Drive Sprocket Remover (1) in between the case and the output shaft sprocket (2).
    GC0095877Courtesy of CHRYSLER GROUP, LLC
  21. Align the holes on the (special tool #10176, Remover, Front Drive Sprocket) Front Drive Sprocket Remover (1) with the bolt holes in the output shaft flange (2), then install the (special tool #10176, Remover, Front Drive Sprocket) Front Drive Sprocket Remover (1) onto the output shaft flange (2).
    GC0095878Courtesy of CHRYSLER GROUP, LLC
  22. Install the (special tool #10176, Remover, Front Drive Sprocket) Front Drive Sprocket Remover Base (1) onto the puller plate.
    GC0095879Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Install the (special tool #10176, Remover, Front Drive Sprocket) Front Drive Sprocket Remover Bearing (1) so that the bearing flange is facing up.

  23. Install the (special tool #10176, Remover, Front Drive Sprocket) Front Drive Sprocket Remover Bearing (1).
    GC0095880Courtesy of CHRYSLER GROUP, LLC
  24. Install the (special tool #10176, Remover, Front Drive Sprocket) Front Drive Sprocket Remover Nut.
    GC0095881Courtesy of CHRYSLER GROUP, LLC
  25. Tighten the nut until the output shaft (1) is pulled free of the output shaft sprocket.
  26. Remove the output shaft sprocket, the drive chain, and the drive sprocket as an assembly.
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