BW 44-47 Transfer Case - Inspection

INSPECTION

MAINSHAFT/SPROCKET/HUB INSPECTION

Inspect the splines on the hub and shaft and the teeth on the sprocket. Minor nicks and scratches can be smoothed with an oilstone. However, replace any part that is damaged.

Check the contact surfaces in the sprocket bore and on the mainshaft. Minor nicks and scratches can be smoothed with 320-400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe.

PLANETARY CARRIER





Examine the planetary carrier body (2) and pinion gears for wear or damage. Check the pinion gear thrust washers on the pinon pins for damage. The carrier will have to be replaced as an assembly if the body, pinion pins, or pinion gears are damaged.

Check the needle bearing in the carrier. Inspect the thrust bearing (1).

SHIFT FORK/HUBS/SLEEVES





Check condition of the shift fork and shift fork shift rail. Minor nicks on the shift rail can be smoothed with 320-400 grit emery cloth.

Inspect the shift fork wear pads (2).

Check the shift fork sleeve (1) for wear or damage.





Check the reduction hub (1) for wear on the shift fork collar (2).

Check the teeth and splines of the reduction hub (1). Minor nicks can be dressed off with an oilstone. Replace the gear if any teeth are broken, cracked, or chipped.

REAR EXTENSION HOUSING

Inspect the extension housing seal and bushing. Replace both components if either show any sign of wear or damage.

FRONT OUTPUT SHAFT AND DRIVE CHAIN

Inspect the shaft splines, sprocket teeth, and bearing surfaces. Minor nicks on the teeth can be smoothed with an oilstone. Use 320-400 grit emery to smooth minor scratches on the shaft bearing surfaces. Rough threads on the shaft can be chased if necessary. Replace the shaft if the splines are damaged, bearing surfaces are scored, or if any sprocket teeth are cracked or broken.

Examine the drive chain and shaft bearings. Replace the chain and both sprockets if the chain is stretched, distorted, or if any of the links bind. Replace the bearings if rough, or noisy.

LOW RANGE ANNULUS GEAR





Inspect the annulus gear (2) condition carefully.

FRONT AND REAR CASES

Inspect the cases for wear and damage.

Check the case condition. If leaks were a problem, look for gouges and severe scoring of the case sealing surfaces. Also make sure the front case mounting studs are in good condition.

Check the front case mounting studs and vent tube. The tube can be secured with Loctite(TM) 271 or 680 if loose. The stud threads can be cleaned up with a die if necessary. Also check the condition of the fill/drain plug threads in the rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired with Helicoil(R) stainless steel inserts if required.

OIL PUMP/OIL PICKUP

Examine the oil pump pickup parts. Replace the pump if any part appears to be worn or damaged. Do not disassemble the pump as individual parts are not available. The pump is only available as a complete assembly. The pickup screen, hose, and tube are the only serviceable parts and are available separately.