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BW44-40 Transfer Case (Service Information): Removal

  1. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
    GC0095857Courtesy of CHRYSLER GROUP, LLC
  2. Remove the transfer case drain plug (2) and allow the transfer case lubricant to drain into a suitable container.
  3. Remove the exhaust. Refer to MUFFLER, EXHAUST, REMOVAL .
  4. Remove the rear drive shaft. Refer to REMOVAL .
    GC0095859Courtesy of CHRYSLER GROUP, LLC
  5. Disconnect the temperature sensor wire harness connector (1) and the clutch coil wire harness connector (2).
    GC0095860Courtesy of CHRYSLER GROUP, LLC
  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 drive shaft. Refer to REMOVAL .
    GC0095861Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The front (transmission) side of the transfer case flange is shown in the illustration 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.
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