Bw 44-44 Transfer Case - Service Information: Specifications RAM Pickup 2500

SPECIFICATIONS

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1. Raise vehicle.
2. Drain transfer case lubricant.
3. Mark front and rear propeller shafts for alignment reference.
4. Support transmission with jack stand.
5. Remove the transfer case skid plate, if equipped.
6. Disconnect front and rear propeller shafts at transfer case.
7. Disconnect transfer case shift motor and mode sensor wire connectors (3).
8. Disconnect transfer case vent hose.
9. Support transfer case with transmission jack.
10. Secure transfer case to jack with chains.
11. Remove nuts attaching transfer case (2) to transmission (1).
12. Pull transfer case and jack rearward to disengage transfer case.
13. Remove transfer case from under vehicle.

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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 shift motor mounting bolts.
3. Remove the center of the electrical connector (1). Carefully disengage the clutch coil wire and remove from connector.
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 retaining ring (1).
7. Remove the spacer (1).
8. Remove bearing (1).
9. Remove the clutch rotor (1).
10. Remove the ball bearings (1) from the apply cam (2).
11. Remove the apply cam (2).
12. Remove the wave spring (1) from the input shaft.
13. Remove the snap ring (1) from the input shaft (2).
14. Remove the clutch assembly (1) from the input shaft (2).
15. Remove the chain (2), front output sprocket (1) and main shaft sprocket (3).
16. Remove lower thrust bearing assembly. Bearing consists of an upper washer (1), bearing (2), and a lower washer (3).
17. Remove magnet (1).
18. Remove oil pump assembly (1).
19. Remove shift assembly (1).
20. Remove main shaft (1).
21. Remove the shift fork (1), reduction hub, and shift rail (2).
22. Remove the carrier assembly (1) and thrust bearing (2).
23. Remove the annulus gear retainer (1).
24. Remove the annulus gear (1).
25. Remove the front output shaft snap ring (1) from the front output shaft (2).
26. Remove the front output shaft (1) from the front housing (2).
27. Remove convoluted cover (1) from coil wire.
28. Remove the coil mounting nuts (2).
29. Remove clutch coil (1) from rear housing.
30. Remove front output shaft seal.
31. Using (special tool #9622, Installer, Countershaft Plug) (1) and (special tool #C-4171, Driver Handle, Universal) (2), remove the front output shaft bearing from the case half (3).
32. Remove input shaft seal.
33. Using (special tool #9622, Installer, Countershaft Plug) (1) and (special tool #C-4171, Driver Handle, Universal) (2), remove the input shaft bearing from the case half (3).
34. Remove rear output shaft seal.
35. Using (special tool #5066, Installer, Bushing) and (special tool #C-4171, Driver Handle, Universal) (1), remove the input shaft bearing from the case half (2).
36. Secure the rear case half.
37. Using (special tool #7794-A, Remover, Seal) (2) and (special tool #C-637, Slide Hammer, Universal) (1), remove front output shaft rear bearing (3) from rear case half.