BW 44-40 Transfer Case - Installation

INSTALLATION

1. Place the PTU on a transmission jack, and raise the PTU up to the rear transmission flange.
2. Align the PTU dowel pins with the holes in the rear transmission flange.





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

3. Install the upper and lower PTU-to-transmission bolts into the upper (1) and lower (2) halves half of the PTU case flange. Tighten the PTU-to-transmission bolts to 55 Nm (41 ft. lb.).

4. Raise the PTU and transmission up into position, and support with a suitable service jack. Remove the transmission jack.
5. Install the front propeller shaft Propeller Shaft - Installation.




6. Install the crossmember (3) and install the bolts attaching the crossmember (1) to frame.
7. Lower transmission with service jack onto crossmember and supports.
8. Install the bolts (2) securing rear support and cushion to transmission crossmember (3).





9. Connect the temperature sensor harness connector (1) and the clutch coil harness connector (2).

10. Install the rear propeller shaft Propeller Shaft - Installation.
11. Install the exhaust Installation.
12. If the fluid was drained, fill the PTU with 1.0L +/- 0.5L (33 oz. +/- 1.7 oz.) of Mobil LT(R) fluid.