BW 44-40 Transfer Case - Removal

REMOVAL

1. Raise and support the vehicle.




2. Remove the transfer case drain plug (2) and allow the transfer case lubricant to drain into a suitable container.
3. Remove the exhaust. Removal
4. Remove the rear propeller shaft Propeller Shaft - Removal.




5. Disconnect the temperature sensor harness connector (1) and the clutch coil harness connector (2).

6. Raise transmission slightly with service jack to relieve load on crossmember and supports.




7. Remove bolts (2) securing rear support and cushion to transmission crossmember (3).
8. Remove bolts attaching the crossmember (1) to frame and remove crossmember (3).

9. Remove the front propeller shaft Propeller Shaft - Removal





NOTE: The front (transmission) side of the transfer case flange is shown for clarity.

10. Remove the lower transfer case-to-transmission bolts from the lower half of the transfer case flange (2).
11. Slightly lower the rear of the transmission to gain access to the upper transfer case to-transmission bolts.
12. Support the transfer case with a transmission jack
13. Remove the upper transfer case to transmission bolts from the upper half of the transfer case flange (1).

14. Remove the transfer case.