BW 44-40 Transfer Case - Assembly

ASSEMBLY

Special Tools:


















1. Check the clearance for the new clutch pack, and select a new spacer if necessary. Adjustments
2. Position the Rear Case Half (3) on an Arbor Press, and position Remover/Installer (1) to support the Rear Case Half (3) from below in the area of the Output Shaft Bearing.
3. Use the Installer (2) and an Arbor Press to install the Output Shaft Bearing into the Rear Case Half (3).





4. Use the Bearing Installer (1) and an Arbor Press to install the Input Shaft Bearing (2) into the rear case half (3).





5. Install the Snubbers (3). Tighten the bolts (1) and (2) to 8 Nm (6 ft. lbs.).
6. Install the Oil Baffle (5). Tighten the Bolts (4) to 8 Nm (6 ft. lbs.).





7. Route the wires through the Rear Case Half (2) and install the Clutch Coil (1) into the Rear Case Half (2).





8. Install the Clutch Coil retainers (1). Tighten to 10 Nm (7 ft. lbs.).





9. Install Clutch Coil Wire Terminal Ends into the Clutch Coil Harness Connector (2), engage the Terminal Ends in the Tabs, then install the Cover (1).

NOTE: If the original convoluted sheath is damaged, install new convoluted sheath

10. Install the Convoluted Sheath and install new tie straps to secure it in position.





11. Install the Wire Retainer (1) on the back of the Clutch Coil Harness Connector (2).





12. Position the Front Case Half (1) on an Arbor Press, and position Seal Installer (2) to support the Input Shaft Seal Flange from below.





13. Use Bearing Installer (1) and an Arbor Press to install the Input Shaft Bearing (2) into the Front Case Half.





14. Use Seal Installer to install the rear input shaft seal into the rear case half (2).





15. Use Seal Installer (1) to install the front input shaft seal into the front case half (2).
16. Use Seal Installer to install the rear output shaft seal into the front case half (2).





17. Use the Bearing Installer and an Arbor Press to install the Output Shaft Bearing into the Front Case Half.





18. Install the Case Magnet (1).





19. Position the Oil Pump Assembly (1) onto the Input Shaft (2).





20. Slide the Oil Pump down until it fully engages the Splines (2) on the Input Shaft (1).
21. Install the Bottom Spacer (4), the Bearing (5), and Top Spacer (6) onto the Input Shaft (1).





22. Install the Input Shaft assembly (1) into the Front Case Half (2).






NOTE: The output shaft sprocket is pressed onto the output shaft.

NOTE: If the Snap Ring (1) is temporarily installed too close to the top of the Output Shaft, it might not be possible to install it into the Bottom Groove on the Output Shaft after the Output Shaft Sprocket is pressed onto the Output Shaft.

23. Temporarily install the Snap Ring (1) approximately 3 mm (0.12 in.) above the Groove (3) on the Output Shaft.
24. Install the Output Shaft Sprocket, the Drive Chain and the Drive Sprocket as an assembly.






NOTE: When the Output Shaft Sprocket (2) is at the correct height, the Top Groove (1) on the Output Shaft will be visible.

25. Use the Installer and an arbor press to install the Output Shaft Sprocket (2) onto the Output Shaft. Press the sprocket until the Top Groove (1) on the Output Shaft is visible.





26. Press the Output Shaft upward with the Output Shaft Flange, then install the Snap Ring (1) into the Groove (3) on the Output Shaft.





27. Install the thrust washer (1) onto the Input Shaft (2).





28. Install a new Clutch Assembly (1) onto the input Shaft (2).





29. Install the Snap Ring (1) onto the Input Shaft (2).





30. Install the wave spring (1) onto the input shaft.





31. Install the apply cam (2), and the ball bearings (1)





32. Install the clutch rotor (1) onto the input shaft.





33. Install the bearing (1) onto the input shaft.





34. Install the spacer (1)
.




35. Apply a bead of Loctite(R) 598 HB to the front case half sealing surface.
36. Install the rear cover (1). Tighten the case bolts to 31 Nm (23 ft. lbs).





37. Install the rear output flange (1)





38. Install a new outer rear output shaft seal (1)





39. Install the rear output flange washer (1)





40. Install the rear output flange nut.
41. Install Holder (1) onto the rear output flange (2). Tighten the rear output flange nut to 319 Nm (235 ft. lbs.).