BW 44-40 Transfer Case - Disassembly

DISASSEMBLY

Special Tools:











NOTE: The vent hole is near the input shaft hub. If the unit is set on the mounting surface, oil will drain out through the vent.

1. Place the transfer case so that it can be drained of any remaining fluid and remove the drain plug (2).





2. Install Holder (1) onto the rear output flange (2).
3. Remove the rear output flange nut.





4. Remove the rear output flange washer (1)





5. Remove the outer rear output shaft seal (1)





6. Remove the rear output flange (1).
7. Remove the case half bolts.






NOTE: The clutch rotor might remain in the rear case half during removal.

8. Remove the rear cover (1)





9. Remove the spacer (1)





10. Remove the bearing (1) from the input shaft.





11. Remove the clutch rotor (1) from the input shaft.





12. Remove the ball bearings (1) from the apply cam (2).
13. Remove the apply cam (2)





14. Remove the wave spring (1) from the input shaft.





15. Remove the snap ring (1) from the input shaft (2).





16. Remove the clutch assembly (1) from the input shaft (2).





17. Remove the thrust washer (1) from the input shaft (2).






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

18. Release the Snap Ring (1) from the Output Shaft and move it away from the Groove (3), toward the Output Shaft Sprocket (2).





19. Slide the Brace Plate (1) in between the case and the input shaft sprocket (2).





20. Align the holes on the Puller Plate (1) with the bolt holes in the output shaft flange (2), then install the Puller Plate (1) onto the output shaft flange (2).





21. Install the Base (1) onto the puller plate.






NOTE: Install the Bearing (1) so that the bearing flange is facing up.

22. Install the Bearing (1).





23. Install the Nut.





24. Tighten the nut until the Output Shaft (1) is pulled free of the output shaft sprocket.
25. Remove the Output Shaft Sprocket, the Drive Chain, and the Drive Sprocket as an assembly.





26. Remove the Input Shaft assembly (1) from the front case half (2).






NOTE: The Top Spacer (6) might remain attached to the Drive Sprocket when it is removed from the Input Shaft (1).

27. Remove the Top Spacer (6) from the Input Shaft (1).





28. Remove the Bearing (1) and the Bottom Spacer (2) from the Input Shaft (3).





29. Remove the Oil Pump Assembly (1) from the Input Shaft (2).





30. Remove the Case Magnet (1).





31. Use the Bearing Race Remover (1) and Slide Hammer (2) to remove the output shaft bearing (3) from the rear case half.
32. Use the Bearing Race Remover (1) and Slide Hammer (2) to remove the input shaft bearing from the rear case half.





33. Use the Bearing Race Remover (1) and Slide Hammer (2) to remove the Output Shaft Bearing (3) from the Front Case Half (4).
34. Use the Bearing Race Remover and Slide Hammer to remove the Input Shaft Bearing from the Front Case Half.





35. Remove the Tie Straps, and remove the Convoluted Sheath from the Clutch Coil Wires.
36. Remove the retainer (1) from the Clutch Coil Harness Connector (2).






NOTE: The clutch coil wires are retained in the harness connector by tabs. The tabs must be released from the connector face to remove the wires from the harness connector.

37. Remove the Cover (1) from the Clutch Coil Harness Connector (2), release the tabs, and disconnect the Clutch Coil Terminal Ends from the Clutch Coil Harness Connector (2).





38. Remove the Clutch Coil retainers (1).





39. Remove the Clutch Coil (1) from the Rear Case Half (2).





40. Remove the Fastener (4) and the Oil Baffle (5).
41. Remove the Fasteners (1) and (2) and the Snubbers (3).
42. Remove the input and output shaft seals from the front case half.
43. Remove the input shaft seal from the rear case half.