BW 44-45 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 (9754) (2) and (C-4171) (1), install the input shaft seal (3).
6. Using (10174) (1), install the front output shaft seal (2).
7. Using (9672) (2) with (C-4171) (1), install the rear output seal (3) into the rear housing (4).
8. Install the lock-up coil (1) in the rear housing.
9. Install the coil mounting nuts (2) and tighten to 9 Nm (84 in. lbs.).
10. Install the convoluted cover (1) on the coil wire.
11. Install the front output shaft (1) into the front housing (2).
12. Install the front output shaft retaining ring (1) on the front the output shaft (2).
13. Install the annulus gear (1).
14. Install the annulus gear retainer (1).
NOTE:
Insure that the thrust bearing is installed with the tabs (notches) facing upward.
15. Install the planetary carrier assembly (1) and thrust bearing (2).
16. Install the shift rail (2), shift fork (1), and reduction hub.
17. Install the main shaft (1).
18. Install the shift assembly (1). Be sure the pin is seated in case.
19. Install the oil pump assembly (1).
20. Install magnet (1).
21. Install the lower thrust washer (1) onto the main shaft (2).
NOTE:
Chain and gears are patterned and must be installed correctly. Blue links on the chain must be installed facing upward.
22. Install the chain (2), front output sprocket (1) and the main sprocket (3).
23. Install the mode shift fork (1), spring and the lock-up assembly (2)
24. Install the lock-up rotor (1).
25. Install the retaining ring (1).
26. Clean the mating surfaces of both case halves.
27. Apply a thin bead of transfer case sealant to mating surfaces.
28. Install the rear cover.
29. Install all of the case half bolts (2) and tighten in a star pattern to 31 Nm (23 ft. lbs.).
30. Install the shift motor mounting bolts (1&2) and tighten to 9 Nm (84 in. lbs.).
31. Carefully install the coil wire into the connector.
32. Install the primary lock (1) into the connector.
33. Install the transfer case into the vehicle. .