Land Rover Borg Warner 44 62 Transfer Box Overhaul Rover Manual

TRANSFER BOX
OVERHAUL7
Refit
1.Clean bearing and VCU casing mating faces.
CAUTION: Do not use a metal scraper as
this may damage sealing surfaces.
2.Press bearing into VCU housing and fit
retaining circlip.
3.Clean sealing area of VCU housing and
running surface of front output shaft drive
flange. Ensure all traces of rubber are
removed.
CAUTION: Do not use a metal scraper as
this may damage sealing surfaces.
4.Using tool LRT-41-013 , drift oil seal into VCU
housing. Ensure the seal is square to housing...

TRANSFER BOX
8
OVERHAUL SELECTOR FORK ASSEMBLY
Service repair no - 41.20.40/01
Remove
1.Remove viscous coupling assembly.See this
section.
2.Remove 17 bolts securing halves of transfer
box casing.
3.Carefully break RTV seal and remove front
transfer box casing from rear casing.4.Remove selector fork assembly, interlock spool
shaft and reduction hub from rear casing.
Collect tube spacer.
5.Remove reduction hub from selector fork
assembly. 

TRANSFER BOX
OVERHAUL9
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.Fit reduction hub to selector fork assembly with
hub splines towards the shorter end of shift rail.
3.Fit tube spacer to interlock spool shaft.
4.Engage selector fork cam follower to interlock
spool cam track.
5.Fit reduction hub to intermediate shaft and
engage interlock spool shaft and shift rail to
holes in rear casing.
6.Rotate...

TRANSFER BOX
10
OVERHAUL REDUCTION HUB
Service repair no - 41.20.70/01
Remove
1.Remove viscous coupling assembly.
See this
section.
2.Remove 17 bolts securing halves of transfer
gearbox casing.3.Carefully break RTV seal and remove front
transfer box casing from rear casing.
4.Remove selector fork assembly, interlock spool
shaft and reduction hub from rear casing.
Collect tube spacer.
5.Remove reduction hub from selector fork. 

TRANSFER BOX
OVERHAUL11
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.Fit reduction hub to selector fork with hub
splines towards the shorter end of shift rail.
3.Fit tube spacer to interlock spool shaft.
4.Engage selector fork cam follower to interlock
spool cam track.
5.Fit reduction hub to intermediate shaft and
engage interlock spool shaft and shift rail to
holes in rear casing.
6.Rotate interlock spool...

TRANSFER BOX
12
OVERHAUL INTERLOCK SPOOL
Service repair no - 41.20.74/01
Remove
1.Remove viscous coupling assembly.
See this
section.
2.Remove 17 bolts securing halves of transfer
box casing.3.Carefully break RTV seal and remove front
transfer box casing from rear casing.
4.Remove selector fork assembly, interlock spool
shaft and reduction hub from rear casing.
Collect tube spacer.
5.Collect interlock spool. 

TRANSFER BOX
OVERHAUL13
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.Fit tube spacer to interlock spool shaft.
3.Engage selector fork cam follower to interlock
spool cam track.
4.Fit reduction hub to intermediate shaft and
engage interlock spool shaft and shift rail to
holes in rear casing.
5.Rotate interlock spool shaft to position
reduction hub and selector fork to low ratio
position, nearest rear casing...

TRANSFER BOX
14
OVERHAUL REAR OUTPUT SHAFT DRIVE FLANGE
Service repair no - 41.20.14/01
Remove
1.Remove screw securing brake drum to flange.
2.Loosen park brake drum adjusting screw.
3.Remove brake drum.
4.Using LRT-51-003 to restrain drive flange,
remove nut securing drive flange to rear output
shaft.
5.Collect washer and seal.
6.Using LRT-99-500 if necessary, remove flange
from output shaft.
Refit
1.Clean running surface of drive flange. Ensure
all traces of rubber are removed.
CAUTION: Do not use a...

TRANSFER BOX
OVERHAUL15
REAR OUTPUT SHAFT OIL SEAL
Service repair no - 41.20.54/01
Remove
1.Remove rear output shaft drive flange.
See
this section.
2.Remove dust shroud from transfer box rear
casing.
3.Using a flat bladed screwdriver free of rough
edges, ease oil seal from rear casing.
CAUTION: Do not mark sealing surface on
rear casing.
4.Remove rear output shaft oil seal.Refit
1.Clean sealing area of rear casing and running
surface of drive flange. Ensure all traces of
rubber are removed.
CAUTION: Do...

TRANSFER BOX
16
OVERHAUL DRIVE CHAIN
Service repair no - 41.20.67/01
Remove
1.Remove rear output shaft drive flange.
See
this section.
2.Remove interlock spool.See this section.
3.Release differential assembly from rear casing
until differential rear bearing is clear of casing.
NOTE: Ensure rear output drive shaft
moves with differential.
4.Tilt differential assembly towards drive
sprocket, take care not to bruise casing.
5.Remove drive chain from gears.
6.Position differential assembly to rest in rear...