Land Rover Lesson 2 Auto Trans Coolingine Rover Manual

Transfer Box Component Location
Instrument cluster1
Range change selection switch2
Transfer box3
Central junction box (CJB)4
Manual transmission output shaft speed sensor5
Gear position sensor (Manual transmission only)6
Transfer box control module7
Four-Wheel Drive SystemsLesson 2 – Powertrain
311Technical Training (G421181) 

Transfer Box Exploded View
Synchronisation spring1
Differential assembly2
Bolt, 6 off3
Spacer ring4
(G421181) Technical Training312
Lesson 2 – PowertrainFour-Wheel Drive Systems 

Shifting sleeve5
Bolt, 3 off6
Solenoid7
Shifting element8
Synchronisation spring9
Circlip10
Ball bearing11
Rear housing12
Circlip13
Seal ring14
Needle roller bearing15
Rear output flange16
Needle roller bearing17
Bolt, 2 off18
Selector fork position sensor19
Bearing20
Circlip21
Transfer box motor assembly22
Bolt, 4 off23
Circlip24
Shifting fork25
Fork pin26
Sliding block27
Actuator assembly28
Fill plug29
Seal ring30
Ball retention31
Drain plug32
Seal ring33
Particle collector magnet34
Sliding block35...

Seal ring71
Front output flange72
Seal ring73
Circlip74
Bearing75
GENERAL
The DD295 transfer box is full time, permanent
four-wheel-drive unit, with 50/50 torque distribution to
the front and rear driveshafts. The unit is manufactured
by Magna Steyr Powertrain in Graz, Austria and
supports the following features:
•Permanent four-wheel-drive with a bevel gear centre
differential, providing a 50:50 torque split
•Selectable high and low range for optimum on-road
and off-road performance
•Two-speed, fully...

Transfer Box - Sectional View
Planetary gear set1
Rear output flange2
Centre differential assembly3
Multi-plate clutch4
Transfer box motor module5
Rear housing assembly6
Front output sprocket7
Chain drive8
Front output flange9
Transfer box motor levers10
Sprocket11
Oil pump assembly12
Input shaft13
Front housing assembly14
Four-Wheel Drive SystemsLesson 2 – Powertrain
315Technical Training (G421181) 

Transfer Box Power Flow
The input torque, from the transmission, is transferred
to the input shaft of the transfer box and then onto the
planetary sun gear and planetary pinion gears. The
planetary pinion gears are held in place by the planet
pinion shafts, which are connected to the differential
carrier, and drive the differential pinion gears. The
torque is then distributed to both the front and rear
carriers, which are connected to the outputs of the
transfer box. The rear carrier is connected...

Front Casing Assembly
The front casing assembly provides the location for the
input shaft bearing and the front output flange bearing.
It is also equipped with threaded holes to mount the
chassis mounting bush, two lifting eyes and a breather
cartridge for the transfer box breather pipe. The breather
pipe allows an equalisation between atmospheric and
internal transfer box pressure.
Rear Casing Assembly
The rear casing assembly provides the location for the
rear output flange bearing, the transfer box...

shifting sleeve (5) into the dogteeth on the clutch control
disc (4). The rotational movement of the motor shaft
(1) is then linked to the clutch control disc via the
shifting sleeve.
This is the normal operating mode of the transfer box.
In this position, the range change function is disengaged
and mechanically locked.
Transfer Box Motor Position For High/Low
Range Mode
Motor shaft1
Solenoid shift fork2
Solenoid3
Shifting sleeve4
Actuation cam5
To actuate the high/low range change, the transfer box...

CENTRE DIFFERENTIAL ASSEMBLY
Synchronisation cup and spring1
Planetary ring gear2
Differential carrier3
Pinion gears4
Pinion gear shafts5
Planetary pinion gears6
Planetary pinion gear shafts7
Planetary sun gear8
Differential cover9
Differential side gears10
Multi-plate clutch basket11
Dogteeth12
The centre differential assembly is the primary feature
of the transfer box. Torque is transmitted through the
centre differential carrier and distributed to the
differential gears and the front and rear output...

The multi-plate clutch basket (11), which is welded to
the differential casing, supports the friction plates, the
dogteeth (12) for high range engagement and the
synchronisation cup and spring (1) for the
shift-on-the-move function.
High range positionA
Low range positionB
Dogteeth1
Planetary pinion gears2
Planetary ring gear3
Shifting sleeve4
Low range dogteeth5
Rear carrier assembly6
When high range is engaged, the shifting sleeve (4)
connects to the differential carrier via dogteeth (1). The
planetary...