BW44-40 Transfer Case (Service Information): Adjustments

Courtesy of CHRYSLER GROUP, LLC

1. Install the oil pump (7), the new clutch assembly (1), the rotor (2), the bearing (6), and the spacer (5) on the input shaft.
2. Install the (special tool #10177, Nut, Lockdown) (3) on the input shaft.
3. Set up a dial indicator (4) to measure the clearance between the rotor (2) and the top clutch disc inside the clutch housing (1).
4. Zero the dial indicator (4).
5. Push the rotor (2) downward evenly as close to the shaft as possible and record the highest reading. Repeat this measurement in three more locations and calculate the average of all four measurements. This is the total amount of clutch clearance.
6. The total clutch clearance must be between 1.2 mm and 0.7 mm (0.047 in. and 0.028 in.). If the total clutch clearance is not within specifications, select a larger or smaller spacer as needed, and re-check clutch clearance.