BW 44-44 Transfer Case - Assembly

ASSEMBLY

Special Tools:










1. Check the clearance for the new clutch pack, and select a new spacer if necessary. Adjustments





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

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






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

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






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

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





6. Using installer (2) and handle (1), install input shaft seal (3).





7. Using installer (1), install front output shaft seal (2).





8. Using installer (2) with drive handle (1), install rear output seal (3).





9. Install clutch coil (1) in rear housing.





10. Install the coil mounting nuts (2) and tighten to 9 Nm (84 in. lbs.).
11. Install convoluted cover (1) on coil wire.





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





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





14. Install the ring gear (1) and install ring gear retainer.





15. Install the carrier assembly (1) and thrust bearing (2).





16. Install the shift rail (2), shift fork (1), and reduction hub.





17. Install main shaft (1).





18. Install shift assembly (1). Be sure pin is seated in case.





19. Install oil pump assembly (1).





20. Install magnet (1).





21. Install lower thrust bearing assembly. Bearing consists of a lower washer (3), bearing (2), and an upper washer (1).






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

22. Install the chain (2), front output sprocket (1) and main shaft sprocket (3).





23. Install the clutch assembly (1) on the input shaft (2).





24. Install the snap ring (1) on the input shaft (2).





25. Install the wave spring (1) on the input shaft.





26. Install the apply cam (2).
27. Install the ball bearings (1) on the apply cam (2).





28. Install the clutch rotor (1).





29. Install bearing (1).





30. Install spacer (1).





31. Install retaining ring (1).





32. Clean mating surface of both case halves.
33. Apply a thin bead of transfer case sealant.
34. Install rear cover.
35. Install all of the case half bolts (2) and tighten in a star pattern (23 ft. lbs.).





36. Carefully install the clutch coil wire into connector. Install the center of the electrical connector (1).





37. Install the shift motor mounting bolts and tighten to 9 Nm (84 in. lbs.).
38. Install transfer case into vehicle. BW 44-44 Transfer Case - Installation