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 divided into 3 sections, Description
and Operation, Overhaul and Torque & Tools. To
assist filing of revised information each sub-section
is numbered from page 1.
Items numbered in the illustrations are referred to in
the text. Overhaul operations include reference to
Service Tool numbers and the associated illustration
depicts the tool. Where usage is not obvious the tool
is shown in use. Operations also include reference
to wear limits, relevant data, torque figures, and
specialist information and useful assembly details.
WARNINGS, CAUTIONSandNOTEShave the
following meanings:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of injury.
CAUTION: Calls attention to procedures
which must be followed to avoid damage
to components.
NOTE: Gives helpful information.References
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the
vehicle is carried out particularly where safety
related items are concerned.
Dimensions
The dimensions quoted are to design engineering
specification with Service limits where applicable. 
						

							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 manufacturers specification.
Torque wrench setting figures given in this Manual
must be used. Locking devices, where specified,
must be fitted. If the efficiency of a locking device is
impaired during removal it must be renewed.
The Terms of the vehicle Warranty may be
invalidated by the fitting of other than Land Rover
recommended parts. All Land Rover recommended
parts have the full backing of the vehicle Warranty.
Land Rover Dealers are obliged to supply only Land
Rover recommended parts.SPECIFICATION
Land Rover are constantly seeking to improve the
specification, design and production of their vehicles
and alterations take place accordingly. While every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
component or vehicle.
This Manual does not constitute an offer for sale of
any particular component or vehicle. Land Rover
Dealers are not agents of Land Rover and have no
authority to bind the manufacturer by any expressed
or implied undertaking or representation. 
						

							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
16.Epicyclic gear set
17.Circlip - bearing retention
18.Bearing - 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 - differential
22.Differential assembly
23.Bearing - differential
24.Circlip - gear retention
25.Rear output shaft 
						

							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 shaft
19.O ring seal - speed sensor
20.Speed sensor
21.Bolt - speed sensor
22.Bolt - ratio control motor to rear casing
23.Ratio control motor 
						

							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 differential unit allows the front and rear output
shafts to rotate at different speeds. A viscous
coupling unit (VCU) limits the amount of slippage
allowed between the front and rear output shafts and
renders a conventional differential lock unnecessary. 
						

							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 reduction hub. The
reduction hub and intermediate shaft rotate at the
same speed as the main gearbox output shaft.
When in Low range (position A) the reduction hub is
driven through the planet carrier. The reduction hub
and intermediate shaft rotate at a lower speed than
the gearbox output shaft. When in transfer neutral,
the reduction hub is positioned between the sun
gear and planet carrier.Changing between ratios is achieved by the
reduction hub sliding along a splined section of the
intermediate shaft to engage with the required gear.
The ratio change mechanism comprises the ratio
control motor, reduction hub, interlock spool and
selector fork.
The interlock spool consists of a shaft which locates
in the front casing and protrudes through the rear
casing to engage with the ratio control motor. The
shaft carries an aluminium casting with a helical cam
track and two springs, which are anchored at one
end to the shaft and at the other to the cam track
casting.