This procedure drains and refills the BorgWarner BV 44-46 transfer case fluid on the 2014 Ram 2500 4WD with 6.7L Cummins diesel engine, ensuring proper lubrication and longevity of the transfer case components.

Warnings

Tools required

Parts

• Transfer case drain plug sealing washer × 1 — 6508468AA or equivalent copper washer
• Transfer case fill plug sealing washer × 1 — 6508468AA or equivalent copper washer

Fluids

• Mopar Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level concrete surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Allow transfer case to cool to ambient temperature if vehicle was recently driven
4. Raise vehicle using appropriate lifting points until transfer case is accessible from beneath
5. Support vehicle securely on jack stands at all four corners, ensuring vehicle is completely level
6. Verify vehicle is stable and level before working underneath
7. Locate transfer case drain plug on bottom rear of transfer case and fill plug on driver side of case

Procedure

1. 1

   Access and clean drain plug area
   Position drain pan directly beneath the transfer case drain plug located at the bottom rear of the transfer case housing. Use wire brush to clean area around drain plug to prevent contamination when plug is removed. Inspect drain plug for damage or rounded hex socket.
2. 2

   Remove drain plug and drain fluid
   Using 10mm hex bit socket and 3/8" ratchet, carefully loosen the drain plug. Once loose, continue removal by hand to prevent dropping plug into drain pan. Allow all fluid to drain completely, which may take 5-10 minutes. Observe drained fluid for excessive metal particles or unusual debris that may indicate internal wear.
   Torque spec

   Transfer Case Drain Plug25 Nm (18 lb-ft)
3. 3

   Clean and inspect drain plug
   Clean drain plug threads and sealing surface with shop rag. Inspect plug threads for damage and replace if stripped or cross-threaded. Remove old sealing washer from drain plug and discard. Verify drain plug magnetic tip (if equipped) and clean any metallic debris. A small amount of fine metallic particles is normal.
4. 4

   Install drain plug with new washer
   Install new copper sealing washer onto drain plug. Thread drain plug into transfer case by hand to ensure proper thread engagement. Once seated, torque drain plug to specification using torque wrench. Do not overtighten as transfer case housing is aluminum and threads can strip.
   Torque spec

   Transfer Case Drain Plug25 Nm (18 lb-ft)
5. 5

   Locate and clean fill plug
   Locate fill plug on driver side of transfer case, approximately mid-height on the case housing. Clean area around fill plug with wire brush to prevent contamination during removal. Position yourself to have clear access for fluid pump insertion.
6. 6

   Remove fill plug
   Using 10mm hex bit socket and 3/8" ratchet, loosen and remove fill plug completely. Remove and discard old sealing washer. Inspect fill plug threads for damage. Place fill plug in clean location where it will not be lost or contaminated.
7. 7

   Fill transfer case with new fluid
   Insert fluid transfer pump nozzle into fill hole. Slowly pump Mopar Transfer Case Fluid into transfer case until fluid begins to drip from fill hole, indicating proper level. The BV 44-46 transfer case requires approximately 2.5 quarts. Allow fluid to settle for 1-2 minutes and top off if level drops below fill hole. Proper fill level is achieved when fluid is at bottom of fill plug threads.
   ⚠Use only Mopar Transfer Case Fluid. Use of incorrect fluid will cause transfer case damage and void warranty coverage.
8. 8

   Install fill plug
   Install new copper sealing washer onto fill plug. Wipe any excess fluid from transfer case housing around fill hole. Thread fill plug into transfer case by hand to ensure proper thread engagement, then torque to specification using torque wrench.
   Torque spec

   Transfer Case Fill Plug25 Nm (18 lb-ft)
9. 9

   Clean and inspect for leaks
   Wipe down entire transfer case exterior to remove any spilled fluid. Inspect both drain and fill plugs for proper seating and any signs of leakage. Check transfer case seals and vent tube for any fluid seepage.
10. 10

    Lower vehicle and perform operational check
    Carefully lower vehicle from jack stands to ground level. Start engine and allow to reach normal operating temperature. With engine at idle and foot on brake, shift transfer case through all positions (2WD, 4WD High, Neutral, 4WD Low) and return to 2WD. Listen for abnormal noises during shifts. Shut off engine.

Reassembly

1. No disassembly was required for this procedure
2. Ensure both drain and fill plugs are torqued to specification with new sealing washers installed
3. Verify no tools or materials are left under vehicle before lowering

Verification

• Re-check both drain and fill plugs for proper torque after vehicle has been lowered
• Start vehicle and verify no warning lights on instrument cluster related to 4WD system
• Test drive vehicle and engage 4WD High at low speed to verify proper transfer case operation and absence of fluid leaks
• After test drive, raise vehicle and inspect transfer case drain and fill plugs for any signs of leakage
• Check transfer case fluid level is still at proper level (at bottom of fill plug hole) after test drive
• Record mileage and date of service for maintenance records

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