BW 44-45 Transfer Case - Disassembly
DISASSEMBLY
Special Tools:
1. Place the transfer case so that it can be drained of any remaining fluid and remove the fill (2) and drain plugs (1).
2. Remove the primary lock (1) at the shift motor connector. Carefully disengage the coil wire and remove from the connector.
3. Remove the shift motor mounting bolts (1&2).
4. Remove all of the case half bolts (2).
5. Carefully, using a prybar at pry points (1), separate and remove the rear case half.
6. Remove the retaining ring (1).
7. Remove the lock-up rotor (1).
8. Remove the mode shift fork (1), spring and the lock-up assembly (2).
9. Remove the chain (2), front output sprocket (1) and main shaft sprocket (3).
10. Remove the lower thrust washer (1) from the main shaft (2).
11. Remove the magnet (1).
12. Remove the oil pump assembly (1).
13. Remove the shift assembly (1).
14. Remove the main shaft (1).
15. Remove the range shift fork (1), reduction hub, and shift rail (2).
16. Remove the planetary carrier assembly (1) and thrust bearing (2).
17. Remove the annulus gear retainer (1).
18. Remove the annulus gear (1).
19. Remove the front output shaft retaining ring (1) from the front output shaft (2).
20. Remove the front output shaft (1) from the front housing (2).
21. Remove the convoluted cover (1) from the coil wire.
22. Remove the coil mounting nuts (2).
23. Remove the lock-up coil (1) from the rear housing.
24. Remove the front output shaft seal.
25. Using remover (9622)(1) and drive handle (C-4171)(2), remove the front output shaft bearing from the case half (3).
26. Remove the input shaft seal.
27. Using remover (9622) (1) and drive handle (C-4171)(2), remove the input shaft bearing from the case half (3).
28. Remove the rear output shaft seal.
29. Using (5066) and (C-4171) (1), remove the input shaft bearing from the case half (2).
30. Secure the rear case half.
31. Using (7794-A) (2) and (C-637) (1), remove the front output shaft rear bearing (3) from the rear case half.