Land Rover Borg Warner 44 62 Transfer Box Overhaul Rover Manual
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TRANSFER BOX OVERHAUL17 DIFFERENTIAL UNIT Service repair no - 41.20.13/01 Remove 1.Remove drive chain. See this section. 2.Remove differential unit from rear output shaft. Refit 1.Fit differential unit to rear output shaft. 2.Fit drive chain. See this section. DIFFERENTIAL BEARINGS Service repair no - 41.20.17/01 Remove 1.Remove differential unit from transfer box. See this section. 2.Using a suitable puller, remove 2 bearings from differential unit. Refit 1.Ensure bearing and differential mating faces are clean. 2.Press bearings onto differential unit. 3.Fit differential unit to transfer box. See this section.
TRANSFER BOX 18 OVERHAUL REAR OUTPUT SHAFT Service repair no - 41.20.18/01 Remove 1.Remove differential unit. See this section. 2.Remove rear output shaft from rear casing. Refit 1.Fit rear output shaft to rear casing. 2.Fit differential unit. See this section. REAR OUTPUT SHAFT BEARING Service repair no - 41.20.19/01 Remove 1.Remove rear output shaft. 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. 5.Remove circlip retaining rear output shaft bearing to rear casing. 6.Press out rear output shaft bearing from rear casing.
TRANSFER BOX OVERHAUL19 Refit 1.Clean bearing and rear casing mating surfaces. 2.Press bearing into rear casing. 3.Fit circlip retaining bearing in rear casing. 4.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. 5.Lubricate sealing surfaces of seal with clean gearbox oil. 6.Using LRT-41-013, fit oil seal to transfer gearbox rear casing. 7.Fit dust shroud to transfer box rear casing. 8.Fit rear output shaft. See this section. INTERMEDIATE SHAFT DRIVE GEAR Service repair no - 41.20.22/01 Remove 1.Remove drive chain. See this section. 2.Remove circlip securing drive gear to intermediate shaft. 3.Remove drive gear from intermediate shaft. Refit 1.Ensure drive gear and intermediate shaft are clean and free from burrs. 2.Fit drive gear to intermediate shaft. 3.Fit circlip retaining drive gear to intermediate shaft. 4.Fit drive chain. See this section.
TRANSFER BOX 20 OVERHAUL INTERMEDIATE SHAFT REAR BEARING Service repair no - 41.20.21/01 Remove 1.Remove intermediate shaft drive gear. See this section. 2.Remove 2 magnets from rear casing. 3.Release oil strainer clip from rear casing. 4.Expand snap ring retaining intermediate shaft rear bearing to rear casing. 5.Remove intermediate shaft, oil pump and strainer assembly from rear casing. 6.Remove circlip retaining intermediate shaft bearing to intermediate shaft. 7.Using a suitable puller, remove bearing from rear of intermediate shaft. Refit 1.Ensure bearing and intermediate shaft mating surfaces are clean and free of burrs. 2.Press bearing onto intermediate shaft. 3.Fit circlip retaining bearing to intermediate shaft. 4.Expand snap ring in rear housing and fit intermediate shaft assembly to rear casing. 5.Ensure snap ring is correctly located to rear bearing. 6.Fit filter hose clip to rear casing. 7.Fit magnets to rear casing. 8.Fit intermediate shaft drive gear. See this section. OIL PUMP Service repair no - 41.20.30/01 Remove 1.Remove intermediate shaft rear bearing. See this section. 2.Remove circlip retaining oil pump to intermediate shaft. 3.Remove washer from intermediate shaft. 4.Remove oil pump and hose assembly from intermediate shaft. 5.Release clip and remove hose from oil pump. Refit 1.Fit hose to oil pump and secure with clip. 2.Fit oil pump to intermediate shaft. 3.Fit washer and circlip securing pump to intermediate shaft. 4.Fit intermediate shaft rear bearing. See this section.
TRANSFER BOX OVERHAUL21 INTERMEDIATE SHAFT Service repair no - 41.20.20/01 Remove 1.Remove oil pump. See this section. 2.Remove circlip from intermediate shaft. Refit 1.Fit circlip to intermediate shaft. 2.Fit oil pump. See this section.
TRANSFER BOX DATA, TORQUE & TOOLS1 TORQUE SETTINGS Output shaft drive flange nut 220 Nm. (162 lbf.ft)................... Front gearcase to rear gearcase bolts 35 Nm. (26 lbf.ft)............ VCU housing to gearcase bolts 35 Nm. (26 lbf.ft)................. Speed sensor 30 Nm. (22 lbf.ft).............................. Drain/Refill plugs 25 Nm. (18 lbf.ft)............................ Temperature sensor 15 Nm. (11 lbf.ft)......................... Ratio control motor to gearcase bolts 10 Nm. (7 lbf.ft)............ Breather hose 10 Nm. (7 lbf.ft).............................. TOOL NUMBERS LRT 41 011 Input shaft oil seal replacer................................ LRT 41 013 Output shaft oil seal replacer................................ LRT 51 003 Drive flange restraining tool................................ LRT 99 500 Drive flange puller................................