BW 44-47 Transfer Case - Assembly

ASSEMBLY

Special Tools:















NOTE: When pressing bearings into the case, be sure to properly support the underside of the case half.

1. Using (9598) (1) and an Arbor Press, install the front output shaft bearing (2) into the front case half (5).
2. Using (9754) (3) and an Arbor Press, install the input shaft bearing (4) into the front case half (5).






NOTE: When pressing bearings into the case, be sure to properly support the underside of the case half.

3. Using (9598) (1) and an Arbor Press, install the rear output shaft bearing (2) into the front case half (3).






NOTE: When pressing bearings into the case, be sure to properly support the underside of the case half.

4. Using (9598) (1) and an Arbor Press, install the front output shaft rear support bearing (2) into the front case half (3).





5. Using i (9754) (2) and (C-4171) (1), install input shaft seal (3).





6. Using (10174) (1), install the front output shaft seal (2).





7. If transfer case is equipped with a flange, and using (9672) (2) with (C-4171) (1), install rear output seal (3).





8. If transfer case is equipped with a slip yoke, and using (9037) (2) with (C-4171) (1), install the rear output seal (3).





9. Install the shift shaft seal (1) in the case (2).





10. Install the front output shaft (1) into the front housing (2).





11. Install the front output shaft snap ring (1) on the front output shaft (2).





12. Install the shift fork lever (1).





13. Install the manual shift lever (1) in the case through the shift fork lever.





14. Using a T20 Torx(R) screwdriver, tighten the retaining screw (1) to 10 Nm (96 in. lbs).





15. Install the detent spring (1) and roller (2) in the shift assembly.





16. Install the detent spring (1) in the pocket in the case.





17. Install the annulus gear (1).





18. Install the annulus gear retainer (1).






NOTE: Bearing tabs face upward.

19. Install the carrier thrust bearing (1) from the center of the planetary (2).





20. Install the planetary carrier (1) into the annulus gear (2).





21. With the shifter (1) rotated fully, install the lower shift fork (2), and the reduction hub (3) as an assembly.





22. Install the main shaft (1).





23. Install the shift shaft (1).





24. Install the magnet (1).





25. Install the oil pump (1).






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.

26. Install the center bearing support assembly (2) on the mainshaft (1).






NOTE: Chain and gears are patterned and must be installed correctly. Blue links on the chain must be installed facing upward.

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





28. Install the mode shift fork, spring and sleeve (1) on the main shaft (2).





29. Install the locking collar (1).





30. Install the retaining ring (1).





31. Clean the mating surface of both case halves.
32. Apply a thin bead of transfer case sealant.
33. Install the rear cover.
34. Install all of the case half bolts and tighten in a star pattern to 31 Nm (23 ft. lbs.).





35. Install the position switch (1) and tighten to 27 Nm (20 ft. lbs.).





36. Install the output flange, if equipped.
37. Install the flange dust seal, if equipped.





38. Install the flange spacer (1), if equipped.





39. Install the rear output flange nut (1) and tighten to 241 Nm (178 ft. lbs.), if equipped.
40. Install the transfer case into vehicle. BW 44-47 Transfer Case - Installation