Land Rover Borg Warner 44 62 Transfer Box Overhaul Rover Manual

BORG WARNER
44-62
TRANSFER BOX
OVERHAUL
MANUAL
This transfer box is used on the
following models:
New Range Rover
Published by Rover Technical Communication
Ó1996 Rover Group Limited
Publication Part No. LRL 0090ENG 

INTRODUCTION
INFORMATION1
INTRODUCTION
How to use this Manual
To assist in the use of this Manual the section title is
given at the top and the relevant sub-section is given
at the bottom of each page.
This Manual contains procedures for overhaul of the
Borg Warner transfer gearbox on the bench. For all
other information regarding General Information,
Adjustments, removal of transmission unit and
ancillary equipment, consult the relevant section of
the New Range Rover Workshop Manual.
This Manual is...

INTRODUCTION
2
INFORMATION REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that only Land Rover recommended parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement
parts and accessories.
Safety features and corrosion prevention treatments
embodied in the vehicle may be impaired if other
than Land Rover recommended parts are fitted. In
certain territories, legislation prohibits the fitting of
parts not to the...

TRANSFER BOX
DESCRIPTION AND OPERATION1
GEARBOX COMPONENTS
1.Front casing - transfer box
2.Bolt - front casing to rear casing
3.Dowel - transfer box to gearbox
4.Viscous coupling
5.Housing - viscous coupling
6.Bolt - viscous coupling housing to front casing
7.Bearing - front output shaft
8.Circlip - bearing retention
9.Oil seal - front output shaft10.Drive flange - front output shaft
11.Sealing washer
12.Plain washer
13.Nut - drive flange
14.Circlip - epicyclic gear to bearing
15.Oil seal - input shaft...

TRANSFER BOX
2
DESCRIPTION AND OPERATION
1.Rear casing - transfer box
2.Dowel - front casing to rear casing
3.Circlip - bearing retention
4.Snap ring - bearing to rear casing
5.Bearing - intermediate shaft
6.Circlip - oil pump retention
7.Shim
8.Oil pump
9.Clip - hose to pump
10.Hose and strainer
11.Magnet
12.Circlip - gear retention
13.Intermediate shaft14.Gear
15.Circlip - gear retention
16.Reduction hub
17.Selector fork assembly
18.Interlock spool
19.Tube spacer
20.Morse chain
21.Bearing -...

TRANSFER BOX
DESCRIPTION AND OPERATION3
1.Rear casing - transfer box
2.Plug - oil drain
3.Plug - oil fill
4.Sealing washer - temperature sensor
5.Temperature sensor
6.Parking brake assembly
7.Bolt - parking brake to rear casing
8.Bearing - rear output shaft
9.Circlip - bearing retention
10.Oil seal - rear output shaft
11.Dust shroud12.Drive flange - rear output shaft
13.Sealing washer
14.Plain washer
15.Nut - drive flange
16.Drum - parking brake
17.Screw - drum to flange
18.Oil seal - interlock spool...

TRANSFER BOX
4
DESCRIPTION AND OPERATION OPERATION
1.Epicyclic gear set
2.Reduction hub
3.Drive gear
4.Selector fork
5.Oil pump
6.Morse chain7.Raito control motor
8.Rear output shaft
9.Differential unit
10.Viscous coupling unit
11.Front output shaft
12.Selector spool 

TRANSFER BOX
DESCRIPTION AND OPERATION5
Introduction
The Borg Warner transfer box splits the drive from
the main gearbox to the front and rear axles through
the propeller shafts. Two speed ratios and a neutral
position are provided by means of a single, epicyclic
gear set. The two speed ratios, High and Low range,
and neutral position are selected electronically by
the ratio control motor.
A Morse chain transmits the drive through a gear
from the intermediate shaft to the differential unit.
The...

TRANSFER BOX
6
DESCRIPTION AND OPERATION High and Low Range
High and Low range are selected by the driver from
a dashboard mounted switch on manual vehicles
and via the selector lever on automatic vehicles.
Transfer neutral is selected by inserting a 5 Amp
fuse in position 11 of the drivers seat fuse box.
Refer to Owners Handbook.
Drive from the main gearbox is permanently
engaged to the sun gear of the epicyclic gear set.
When in High range (position B) the sun gear
transmits drive directly to the...