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

WARNING: This page is about a different variant/trim than selected.
GC0095857Courtesy of CHRYSLER GROUP, LLC
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.

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

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

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

  18. 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
  19. Slide the Front Drive Sprocket Remover (special tool #10176, Remover, Front Drive Sprocket) (1) in between the case and the output shaft sprocket (2).
    GC0095877Courtesy of CHRYSLER GROUP, LLC
  20. Align the holes on the Front Drive Sprocket Remover (special tool #10176, Remover, Front Drive Sprocket) Puller Plate (1) with the bolt holes in the output shaft flange (2), then install the Front Drive Sprocket Remover(special tool #10176, Remover, Front Drive Sprocket) Puller Plate (1) onto the output shaft flange (2).
    GC0095878Courtesy of CHRYSLER GROUP, LLC
  21. Install the Front Drive Sprocket Remover (special tool #10176, Remover, Front Drive Sprocket) Base (1) onto the puller plate.
    GC0095879Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  22. Install the Front Drive Sprocket Remover (special tool #10176, Remover, Front Drive Sprocket) Bearing (1).
    GC0095880Courtesy of CHRYSLER GROUP, LLC
  23. Install the Front Drive Sprocket Remover (special tool #10176, Remover, Front Drive Sprocket) nut.
    GC0095881Courtesy of CHRYSLER GROUP, LLC
  24. Tighten the nut until the output shaft (1) is pulled free of the output shaft sprocket.
  25. Remove the output shaft sprocket, the drive chain, and the drive sprocket as an assembly.
    GC0095882Courtesy of CHRYSLER GROUP, LLC
  26. Remove the input shaft assembly (1) from the front transfer case half (2).
    Fig 1: Input Shaft Exploded View
    GC0095883Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The top spacer (6) might remain attached to the drive sprocket when it is removed from the input shaft (1).

  27. Remove the top spacer (6) from the input shaft (1).
    GC0095884Courtesy of CHRYSLER GROUP, LLC
  28. Remove the bearing (1) and the bottom spacer (2) from the input shaft (3).
    GC0095885Courtesy of CHRYSLER GROUP, LLC
  29. Remove the oil pump assembly (1) from the input shaft (2).
    GC0095886Courtesy of CHRYSLER GROUP, LLC
  30. Remove the transfer case magnet (1).
    GC0095887Courtesy of CHRYSLER GROUP, LLC
  31. Use the (special tool #9585, Remover, Bearing Cup) Bearing Cup Remover (1) and (special tool #C-637, Slide Hammer, Universal) Slide Hammer (2) to remove the output shaft bearing (3) from the rear transfer case half.
  32. Use the (special tool #9585, Remover, Bearing Cup) Bearing Cup Remover (1) and (special tool #C-637, Slide Hammer, Universal) Slide Hammer (2) to remove the input shaft bearing from the rear transfer case half.
    GC0095888Courtesy of CHRYSLER GROUP, LLC
  33. Use the (special tool #9585, Remover, Bearing Cup) Bearing Cup Remover (1) and (special tool #C-637, Slide Hammer, Universal) Slide Hammer (2) to remove the output shaft bearing (3) from the front transfer case half (4).
  34. Use the (special tool #9664, Remover, Bearing Cup) Bearing Cup Remover and (special tool #C-637, Slide Hammer, Universal) Slide Hammer to remove the input shaft bearing from the front transfer case half (4).
    GC0095889Courtesy of CHRYSLER GROUP, LLC
  35. Remove the tie straps, and remove the convoluted sheath from the clutch coil wires.
  36. Remove the retainer (1) from the clutch coil wire harness connector (2).
    GC0095890Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The clutch coil wires are retained in the wire harness connector by tabs. The tabs must be released from the connector face to remove the wires from the wire harness connector.

  37. Remove the cover (1) from the clutch coil wire harness connector (2), release the tabs, and disconnect the clutch coil terminal ends from the clutch coil wire harness connector (2).
    GC0095891Courtesy of CHRYSLER GROUP, LLC
  38. Remove the clutch coil nuts (1).
    GC0095892Courtesy of CHRYSLER GROUP, LLC
  39. Remove the clutch coil (1) from the rear transfer case half (2).
    GC0095893Courtesy of CHRYSLER GROUP, LLC
  40. Remove the fastener (4) and the oil baffle (5).
  41. Remove the fasteners (1) and (2) and the snubbers (3).
  42. Remove the input and output shaft seals from the front transfer case half.
  43. Remove the input shaft seal from the rear transfer case half.
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