Land Rover Borg Warner 44 62 Transfer Box Overhaul Rover Manual

TRANSFER BOX
DESCRIPTION AND OPERATION7
The selector fork is mounted on a second shaft
located within the front and rear casings but is able
to slide in the casing mountings. A cam follower on
the selector fork engages with the cam track of the
interlock spool. When the ratio control motor rotates
the interlock spool, the cam follower of the selector
fork follows the cam track of the interlock spool. This
converts rotational movement of the interlock spool
into linear movement of the selector fork.
The...

TRANSFER BOX
8
DESCRIPTION AND OPERATION Differential unit
The differential unit is driven from the intermediate
shaft through a Morse chain. The outer casing of the
differential unit is the differential input, while the sun
gear provides the front output and the planet carrier
the rear output.The planet carrier contains three sets of gears,
which mesh in pairs to maintain the correct
directional relationship between front and rear
differential outputs. The rear output shaft passes
through the...

TRANSFER BOX
DESCRIPTION AND OPERATION9
Viscous coupling (VCU)
The VCU comprises a short cylinder which contains
an inner shaft with slotted discs attached to its outer
surface, and a similar set of discs attached to the
inner surface of the cylinder. Both sets of discs are
arranged so that they interleave alternately and in
close proximity to each other. The VCU is sealed,
and filled with a type of silicone jelly which has the
property of increasing its viscosity with rises in
temperature and shear...

TRANSFER BOX
10
DESCRIPTION AND OPERATION Lubrication
Internal lubrication of the transfer gearbox is
provided by a low pressure, plunger-type oil pump
mounted on the rear of the intermediate shaft. Oil
pick-up is through a strainer in the transfer box
sump. From the pump, oil is supplied through the
intermediate shaft to the epicyclic gear set. The
differential and Morse chain are partially immersed
in oil and lubricated as the components rotate. The
VCU is a fully sealed unit and does not require...

TRANSFER BOX
OVERHAUL1
RATIO CONTROL MOTOR
Service repair no - 41.30.03/01
Remove
1.Remove 4 bolts securing motor to transfer box.
2.Remove motor.
Refit
1.Fit motor and engage to drive spindle.
2.Tighten bolts to 10 Nm. (7 lbf.ft).INPUT SHAFT OIL SEAL
Service repair no - 41.20.50/01
Remove
1.Using a flat bladed screwdriver free of rough
edges, ease input shaft oil seal from transfer
box front casing.
CAUTION: Do not mark sealing surface of
front casing.
Refit
1.Clean sealing surface of front casing and...

TRANSFER BOX
2
OVERHAUL FRONT OUTPUT SHAFT DRIVE FLANGE
Service repair no - 41.20.15/01
Remove
1.Using LRT-51-003 to restrain front output shaft
drive flange, remove and discard nut securing
drive flange to front output shaft.
2.Collect washer and seal.
3.Using LRT-99-500 if necessary, remove drive
flange from front output shaft.Refit
1.Clean running surface of drive flange. Ensure
all traces of rubber are removed.
CAUTION: Do not use a metal scraper as
this may damage sealing surface.
2.Fit drive flange...

TRANSFER BOX
OVERHAUL3
FRONT OUTPUT SHAFT OIL SEAL
Service repair no - 41.20.51/01
Remove
1.Remove front output shaft drive flange.
See
this section.
2.Using a flat bladed screwdriver free of rough
edges, ease front output shaft oil seal from
front casing.
CAUTION: Do not mark sealing surface of
front casing.
3.Remove oil seal.Refit
1.Clean sealing area of front casing and running
surface of front drive flange. Ensure all traces
of rubber are removed.
CAUTION: Do not use a metal scraper as
this may...

TRANSFER BOX
4
OVERHAUL VISCOUS COUPLING UNIT (VCU)
Service repair no - 41.20.66/01
Remove
1.Remove front output shaft drive flange.
See
this section.
2.Remove 6 bolts securing VCU housing to
transfer box.
3.With care, break front face RTV seal and
remove VCU assembly.
Do not carry out further dismantling if
component is removed for access only.
4.Press out viscous coupling from housing.
CAUTION: Protect output shaft thread and
do not use excessive force when pressing
out viscous coupling.
Refit
1.Clean...

TRANSFER BOX
OVERHAUL5
5.Using a flat bladed screwdriver free of rough
edges, ease input shaft oil seal from front
casing.
CAUTION: Do not mark sealing surface of
front casing.
6.Release circlip retaining epicyclic gear to front
casing. Epicyclic gear set will fall onto block of
wood.
7.Remove epicyclic gear set.Refit
1.Clean RTV sealant from front and rear casing
mating surfaces.
CAUTION: Do not use a metal scraper as
this may damage sealing surfaces.
2.Clean bearing and input shaft mating faces....

TRANSFER BOX
6
OVERHAUL INPUT SHAFT BEARING
Service repair no - 41.20.65/01
Remove
1.Remove epicyclic gear set.
See this section.
2.Remove snap ring retaining input shaft bearing
to front casing.
3.Press out input shaft bearing.
Refit
1.Clean bearing and front casing mating faces,
ensure casing is free from burrs.
2.Press bearing into front casing.
3.Fit snap ring retaining bearing to front casing.
4.Fit epicyclic gear set.
See this section.
FRONT OUTPUT SHAFT BEARING
Service repair no - 41.20.08/01...