Land Rover Range Rover Classic Workshop 1995 Rover Manual

R380
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Bottom cover to clutch housing 8...................................................................
Extension case to gearcase 25.......................................................................
Slave cylinder to bell housing 25....................................................................
Bell housing to gearbox...

BORG WARNER
1
DESCRIPTION AND OPERATION DESCRIPTION
The Borg Warner transfer gearbox incorporates a
single epicyclic gear set which is driven by the main
gearbox output shaft to provide high, neutral or low
gear ratios.
With high or low gear selected, power is transmitted
by a Morse Chain to the front and rear output shafts
via a differential and a limited slip viscous unit.
The gear lever allows neutral, high or low to be
selected. A differential lock is not necessary as this
function is automatically...

41TRANSFER GEARBOX
2
DESCRIPTION AND OPERATION Power flow - operation
Broken lines in the following Illustration indicate
gear or sliding splined connections.High ratio
Moving the gear lever to the high position seen in
RR3551M causes the sleeve 3 to engage directly with
the sun gear 2, allowing the power to by-pass the
planetary gear set 5 and provide a direct drive to the
drive sprocket 7, and Morse chain 8 to the differential
and output shafts. 

BORG WARNER
3
DESCRIPTION AND OPERATION Low ratio
In low gear the selector sleeve 3 connects with the
planet carrier 6 and planet gears 5 to provide low
ratio. 

41TRANSFER GEARBOX
4
DESCRIPTION AND OPERATION Differential and viscous coupling
The Morse chain 8 drives a conventional type
differential 9. The front and rear output shafts 10 and
11 are splined to the differential output pinions. The
front output shaft 10 forms the outer member of the
viscous coupling, while the inner member plates are
splined to the rear output shaft 11.
Its only function is to limit the maximum difference in
speed between the two shafts, with the effect of
automatically locking the...

BORG WARNER
1
FAULT DIAGNOSIS BORG WARNER - SYMPTOMS
Oil leaks
1.Check that nylon ventilation pipes are not
blocked or damaged.
2.Check lubrication level and specification in both
boxes and recheck leaks.
3.Location area of leak.
A - Transfer box front output flange oil seal.
B - Transfer box rear output flange oil seal.
C - Oil leaking from vent hole between main
and transfer boxes.
The oil may be leaking from the main or
transfer box oil seals. Renew the faulty
seal.
D - Oil leaking from engine...

BORG WARNER
1
REPAIR REAR OUTPUT SHAFT OIL SEAL
Service tool: 18G1422
1.Disconnect rear propeller shaft from output drive
flange and tie shaft to one side.
2.Apply parkbrake and release drive flange nut.
3.Release parkbrake and remove brake drum
secured with two screws.
4.Remove output shaft nut, steel washer, rubber
seal and withdraw flange.
5.Tap dust cover from housing and remove oil
seal.
6.Lubricate and fit new seal using service tool
18G1422. Fit so spring side of seal abuting
circlip.
7.Fit dust...

41TRANSFER GEARBOX
2
REPAIR BORG WARNER TRANSFER GEARBOX
Service repair no - 41.20.25
Remove
1.Site vehicle on ramp and chock wheels.
2.Disconnect battery negative lead.
3.Remove fan blade assembly.
NOTE: The nut securing viscous unit has
left hand thread.
4.Disconnect airflow meter to plenum chamber
hose. (V8i only)
5.Remove two gear lever knobs. If Automatic type
remove gear selector.
See ELECTRICAL,
Repair, Automatic Gear Selector-Panel Bulb
6.Remove floor mounted console assembly.See
CHASSIS AND...

BORG WARNER
3
REPAIR Remove transmission assembly
19.Position a suitable transmission hoist on rear
output housing to support weight of assembly.
20.Remove fixings and withdraw transfer gearbox
mountings.
21.Fit adaptor plate to transmission hoist. Raise
hoist and position under transfer box.
See
Service tools, Adapter Plate Transfer Box
NOTE: Centralise adaptor plate on hoist
platform so split line of gearbox is aligned
with centre of ram.
22.Secure fixture to transfer box mounting points.
23.Remove...

41TRANSFER GEARBOX
4
REPAIR
28.Remove high/low rod from gearbox selector
lever.
29.Support main gearbox with hoist and detach
transfer gearbox.
30.Remove upper and lower bolts and two nuts
securing transfer box to main gearbox.
31.Move transfer gearbox rearwards to detach it.
Refit Transfer Gearbox
1.Clean joint faces of transfer gearbox and main
gearbox.
2.Lubricate oil seal in joint face of transfer
gearbox.
3.Fit gearbox to adaptor plate on hoist. Raise hoist
until input shaft enters transfer...