Land Rover Borg Warner 44 62 Transfer Box Overhaul Rover Manual
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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 bore. 5.Fit VCU to housing. See this section.
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 interlock spool shaft to position reduction hub and selector fork to low ratio position, nearest rear casing half. Ensure tube spacer is in position and selector fork cam follower is correctly engaged in interlock spool. 7.If removed, fit 2 dowels into front casing. 8.Apply a continuous 2 mm bead of RTV sealant to rear casing mating face. Path to be around inside of bolt holes. 9.Fit front casing to rear casing, ensure bolt holes and dowels are aligned before disturbing RTV sealant. 10.Fit bolts securing front casing to rear casing and progressively tighten to 35 Nm. (26 lbf.ft) 11.Check freedom of rotation of input shaft and that rear output shaft rotates. 12.Fit viscous coupling assembly. See this section.
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 shaft to position reduction hub and selector fork to low ratio position, nearest rear casing half. Ensure tube spacer is in position and selector fork cam follower is correctly engaged to interlock spool. 7.If removed, fit 2 dowels to front casing. 8.Apply a continuous 2 mm bead of RTV sealant to rear casing mating face. Path to be around inside of bolt holes. 9.Fit front casing to rear casing, ensure bolt holes and dowels are aligned before disturbing RTV sealant. 10.Fit bolts securing front casing to rear casing and progressively tighten to 35 Nm. (26 lbf.ft) 11.Check freedom of rotation of input shaft and that rear output shaft rotates. 12.Fit viscous coupling assembly. See this section.
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 half. Ensure tube spacer is in position and selector fork cam follower is correctly engaged in interlock spool. 6.If removed, fit 2 dowels into front casing. 7.Apply a continuous 2 mm bead of RTV sealant to rear casing mating face. Path to be around inside of bolt holes. 8.Fit front casing to rear casing, ensure bolt holes and dowels are aligned before disturbing RTV sealant. 9.Fit bolts securing front casing to rear casing and progressively tighten to 35 Nm. (26 lbf.ft) 10.Check freedom of rotation of input shaft and that rear output shaft rotates. 11.Fit viscous coupling assembly. See this section.
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 metal scraper as this may damage sealing surface. 2.Fit drive flange to rear output shaft. 3.Fit seal, washer and new nut to rear output shaft. 4.Using LRT-51-003 to restrain drive flange, tighten nut to 220 Nm. (162 lbf.ft) 5.Fit brake drum to drive flange and secure with screw. 6.Adjust park brake drum screw. See New Range Rover Workshop Manual.
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 not use a metal scraper as this may damage sealing surfaces. 2.Lubricate sealing surfaces of seal with clean gearbox oil. 3.Using LRT-41-013 fit oil seal to transfer box rear casing. 4.Fit dust shroud to transfer box rear casing. 5.Fit rear output shaft drive flange. See this section.
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 casing.Refit 1.Position differential assembly towards drive gear and fit drive chain to both gears. 2.Engage chain to gears and align differential rear bearing to rear casing. 3.Engage differential rear bearing to rear casing and output shaft to output shaft bearing. 4.Fit interlock spool. See this section. 5.Fit rear output shaft drive flange.See this section.