Transfer Case Chain

This procedure covers the removal and replacement of the transfer case chain in a BW 44-47 transfer case, including disassembly of the transfer case housing.

Warnings

Tools required

Parts

• Transfer case chain × 1 — Use OEM specification for BW 44-47
• Transfer case gasket kit × 1 — Use OEM specification
• Transfer case output shaft seal (front) × 1 — Use OEM specification
• Transfer case output shaft seal (rear) × 1 — Use OEM specification
• Input shaft seal × 1 — Use OEM specification
• RTV silicone sealant (anaerobic) × 1 — Mopar Three Bond 1207B or equivalent
• Transfer case mounting bolts × 1 — Use OEM specification if reuse not recommended

Fluids

• ATF+4 — 3 qt

Preparation

1. Park vehicle on level surface and set parking brake
2. Disconnect negative battery cable
3. Raise vehicle and support securely on jack stands at frame rails
4. Remove front and rear driveshafts, marking their orientation to flanges for reassembly
5. Place drain pan under transfer case and remove drain plug to drain fluid completely
6. Disconnect transfer case shift linkage or electrical connector from mode motor (if equipped)
7. Support transmission with jack to prevent movement when transfer case is removed
8. Position transmission jack under transfer case for support

Procedure

1. 1

   Remove transfer case from vehicle
   Remove the transfer case-to-transmission mounting bolts (typically 5-6 bolts). Carefully slide transfer case rearward off transmission output shaft. Lower transfer case using transmission jack and remove from under vehicle. Transport to clean workbench for disassembly.
2. 2

   Clean exterior and mark case halves
   Thoroughly clean exterior of transfer case to prevent contamination during disassembly. Use marker or paint pen to mark the front and rear case halves at multiple locations for alignment reference during reassembly. Mark the planetary gear carrier and output shaft orientations as well.
3. 3

   Remove mode motor and shift components
   Remove mode motor or shift sector assembly (depending on configuration). Remove detent spring and ball. Remove shift fork retaining bolts and remove shift fork assembly. Note the position of all components and any alignment marks.
4. 4

   Separate case halves
   Remove all case half bolts in a crisscross pattern. Install case spreader tool or spreader plates at designated points on case. Carefully spread case halves apart using spreader tool. Use plastic mallet to gently tap case halves apart if needed. Separate rear case half from front case half, keeping track of all components.
   ⚠Do not use excessive force or pry tools that may damage case mating surfaces. Case spreader tool is essential to prevent warping.
5. 5

   Remove planetary assembly and chain
   Lift out planetary gear assembly from front case half. Remove the drive chain from the input sprocket and output shaft sprocket. Mark the sprocket orientation relative to shafts before removal. Inspect sprockets for wear or damage and replace if necessary.
6. 6

   Inspect internal components
   Thoroughly inspect all internal components including bearings, sprockets, planetary gears, and case bores for wear, damage, or scoring. Check chain wear by measuring length and comparing to service specifications. Inspect case mating surfaces for damage or warping. Replace any worn or damaged components.
   ℹ️Chain stretch beyond 1% of original length or any sprocket tooth damage requires replacement.
7. 7

   Clean all components and case halves
   Clean all internal components, bearings, and case halves thoroughly using cleaning solvent. Remove all old gasket material and RTV sealant from case mating surfaces using gasket scraper. Ensure all passages are clean and free of debris. Blow out all passages with compressed air and allow to dry completely.
8. 8

   Install new chain and reassemble internals
   Install new chain onto input sprocket and output shaft sprocket, ensuring proper orientation per alignment marks. Install planetary assembly into front case half, aligning all components per reference marks. Verify smooth rotation of all components. Install any snap rings or retaining components removed during disassembly.
   ℹ️Lubricate all internal components with clean ATF+4 during assembly to prevent dry start damage.
9. 9

   Apply sealant and join case halves
   Apply thin, even bead of RTV silicone sealant (Mopar Three Bond 1207B or equivalent) to rear case half mating surface. Avoid excess sealant that may squeeze into case. Carefully align rear case half to front case half using alignment marks made during disassembly. Install case spreader and compress halves together evenly.
   ⚠Sealant must be anaerobic type suitable for transfer case applications. Allow sealant to cure per manufacturer specifications before filling with fluid.
10. 10

    Install case bolts and measure case spread
    Install all case half bolts finger tight in a crisscross pattern. Gradually tighten bolts in multiple passes using crisscross pattern to draw case halves together evenly. Use dial indicator to measure case spread at designated measurement points. Case spread should be within specification (typically 0.005-0.015 inches depending on chain type). Adjust as necessary.
    ℹ️Proper case spread is critical for chain life. Too tight causes excessive chain wear; too loose causes noise and potential failure.
11. 11

    Install shift components and mode motor
    Install shift fork assembly and tighten retaining bolts. Install detent ball and spring. Install mode motor or shift sector assembly, ensuring proper engagement with shift fork. Verify shift operation moves smoothly through all ranges before final installation.
12. 12

    Replace seals and install transfer case
    Install new input shaft seal, front output shaft seal, and rear output shaft seal using seal driver or appropriate socket. Ensure seals are seated flush and square. Raise transfer case into position using transmission jack. Align input shaft with transmission output shaft and slide transfer case forward. Install and tighten mounting bolts in crisscross pattern.
    ⚠Do not allow transfer case to hang on transmission output shaft. Support weight with transmission jack during installation.
13. 13

    Reconnect components and fill fluid
    Reconnect shift linkage or mode motor electrical connector. Install front and rear driveshafts, aligning marks made during removal. Install drain plug with new seal or washer. Fill transfer case with approximately 1.9 quarts of ATF+4 through fill plug opening. Fill until fluid begins to run out of fill hole. Install fill plug.

Reassembly

1. Torque all fasteners to manufacturer specifications using appropriate torque sequence
2. Verify driveshaft alignment marks match original orientation to prevent vibration
3. Double-check all electrical connections and shift linkage for proper operation
4. Remove transmission jack and lower vehicle from jack stands

Verification

• Reconnect battery and start engine, allowing to reach operating temperature
• With engine running and foot on brake, shift transfer case through all ranges (2WD, 4WD High, Neutral, 4WD Low) and verify smooth engagement
• Test drive vehicle in safe area, testing all transfer case modes for proper operation
• Check for fluid leaks around all seals, case mating surface, and drain/fill plugs
• Verify no unusual noises from transfer case during operation in any mode
• Recheck fluid level after test drive and top off if necessary

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