BorgWarner TTS(Beijing) Co., Ltd.
BW 47-36 Transfer Case Service Manual
NOTE: Pump can be tested by immersing filter in oil and rotating shaft in counterclockwise direction when viewed from output end.
a. Push hose (24) onto barb on strainer (25).
b. Slip hose clamp (23) over free end of hose (24) and push hose onto barb on pump (22). Secure hose clamp over hose on barb. c. Align flat surface of pump (22) ID with that of rear output shaft (21) journal. Install pump over rear output shaft. d. Insert rear output shaft (21) into reduction hub (20). 5-2-7. INSTALLATION OF CHAIN DRIVE
To assembly as completed thus far, assemble parts as follows (see Figure 5-12):
a. On work bench, next to case assembly, position drive sprocket (34) at rear output shaft (21) end and driven sprocket (47) at front output shaft end (46). b. Assemble drive chain (49) around sprockets (34 and 47) with blue marked link facing up.
c. Grasp each sprocket (34 and 47), hold drive chain (49) tight and parallel with case (2) and install chain drive assembly over output shafts (21 and 46). It may be necessary to rotate driven sprocket (47) slightly to engage splines on front output shaft (46). d. Install spacer (48) on front output shaft (46). 5-2-8. INSTALLING LOCKUP SHIFT PARTS
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BorgWarner TTS(Beijing) Co., Ltd.
BW 47-36 Transfer Case Service Manual
To assembly as completed thus far, install parts as follows (see Figure 5-13):
a. Assemble return spring (32), lockup hub (31), return spring (30), armature (29) in lockup collar (33) and retain with snap ring (28) completing 2H-4H lockup assembly (84). b. Install rail shaft (36) in case, through reduction shift fork assembly previously installed and into blind hole in case. c. Engage lockup fork (37) in groove in 2H-4H lockup assembly and slide this group down over rear output shaft (21) and rail shaft (36). d. Install electric shift cam group previously assembled (paragraph5-2-4) and cam/coil housing assembly (27) as follows:
a) Position electric shift cam group as shown in Figure 5-14, rotated so that end of torsion
spring will contact side of reduction shift fork assembly (38) that faces up, toward top of case. b) Holding rail shaft (36) down, raise up fork assemblies (37 and 38) slightly. Rotate electric shift
cam group into position so that roller on reduction shift fork assembly (38) is in groove in shift cam (39) and button on lockup fork (37) is on cam end. Then lower this group of parts into the case engaging shift shaft (42) on pin in case. c) Position cam/coil housing assembly (27) in case over rear output shaft (21). Make sure
splines engage. 5-2-9. COVER ASSEMBLY
Assemble parts into cover as follows (see Figure 5-15):
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BorgWarner TTS(Beijing) Co., Ltd.
BW 47-36 Transfer Case Service Manual
a. Position cover (50) on bed of suitable press so that open face of cover is up and parallel with press bed. b. Press in ball bearings (52 and 53) to bottom in cover (50) and install snap ring (51). c. Flip cover over, place tune wheel (54) and drive speedo gear (55) in cover in sequence. d. Position new oil seals (56 and 57) as shown in Figure 5-16 and press in to dimension.
e. To install coil assembly, verify four O-rings (one on wire and one each on three studs) are in place on clutch coil assembly (26). Install clutch coil assembly in inside of cover (50), with electrical wire and studs extending through cover. Use care not to kink or trap electrical wire under clutch coil assembly. Attach with three nuts (64) and torque to 8~11 Nm. 5-2-10. INSTALLING COVER ASSEMBLY
Install cover assembly as completed in paragraph 5-2-9 on case assembly as follows (see Figure 5-17):
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BorgWarner TTS(Beijing) Co., Ltd.
BW 47-36 Transfer Case Service Manual
a. Install return spring (35) over rail shaft (36) in case to rest on shift fork. b. Install magnet (45) in slot in case (2).
c. Apply continuous 1.6 mm bead of sealant (Neutral Cure RTV, Loctite 598) all around case
mounting face for cover assembly. Center sealant bead between edges of face. Circle bolt holes. CAUTION: In the following step do not use excessive force in an attempt to seat cover on transfer case. When all of the alignment conditions specified are met, the cover will seat without using undue force. If not, remove cover assembly and check alignment conditions.
d. Install cover assembly (83) on case (2). All of the following alignment conditions must be met for the cover assembly to seat on case properly (see Figure 5-18):
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