Land Rover Range Rover Classic Workshop 1995 Rover Manual

BORG WARNER
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OVERHAUL BORG WARNER GEARBOX ILLUSTRATED
ASSEMBLIES
Service repair no - 41.20.28
1. Front output housing assembly
2. Viscous unit 

41TRANSFER GEARBOX
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OVERHAUL 1. Rear output housing and output shaft assembly
2. Transmission brake drum assembly
3. Speedometer drive pinion assembly 

BORG WARNER
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OVERHAUL 1. Front cover - main casing
2. Transfer sprocket, centre differential assembly,
driven sprocket and chain
3. Bearing carrier and transfer shaft
4. Selector fork and lever assembly
5. Selector sleeve6. Oil pickup pipe and filter
7. Planetary set (epicyclic unit)
8. Rear cover - main case
9. End cap 

41TRANSFER GEARBOX
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OVERHAUL BORG WARNER TRANSFER GEARBOX
DISMANTLING, OVERHAUL AND REASSEMBLY
Service Tools.
See Service tools, Adapter Plate
Transfer Box
18G1422 - Oil seal replacer
18G1205 - Adjustable flange holding wrench
18G134 - Bearing and oil seal replacer
LST550 - 6 - Input shaft oil seal replacer
NOTE: Before commencing the overhaul
procedure thorougly clean the exterior of
the transfer gearbox. If the gearbox oil has
not previously been drained, drain the oil into a
suitable container....

BORG WARNER
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OVERHAUL 4.Clean any previous sealant from the threads of
the bolts.
5.Using two levers between the cast lugs on the
outer edges of the casing, to assist in separating
the gearbox, carefully prise the front cover from
the rear cover.
CAUTION: Do not lever between the
mating faces.
Transfer sprocket, centre differential, assembly
and chain
NOTE: Before dismantling, mark one chain
link and corresponding tooth on the
transfer sprocket with an identification
line. This is to ensure that the...

41TRANSFER GEARBOX
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OVERHAUL Selector fork assembly
13.Using Torx bit 25 remove the screw securing the
selector arm to the selector lever shaft.
14.Remove the retaining clip securing the selector
fork arm to the selector lever shaft.
15.Using Torx bit 25 remove the screw retaining the
selector lever.
16.Remove the selector lever shaft from the case
and fork assembly.
17.Withdraw the selector fork assembly and
selector sleeve.
18.Retrieve the selector plunger and spring from the
rear cover.
Planetary set...

BORG WARNER
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OVERHAUL DISMANTLE, INSPECTION AND OVERHAUL
Rear cover main case - Dismantle and inspection
1.Remove the circlip retaining the bearing in the
rear cover.
2.Drive or press the bearing from the cover and
discard the bearing.
3.Remove any previous sealant evident on the
rear cover joint faces.
4.Using a suitable solvent thoroughly clean the
cover.
5.Examine the cover for damage, cracks and
porosity, renew if necessary.
6.Check the selector lever shaft bore, for ovality
and wear. If worn renew...

41TRANSFER GEARBOX
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OVERHAUL Front cover main case - Assemble
15.Lubricate a new oil seal. Using service tool LST
550 - 6 in conjunction with bearing and oil seal
replacer 18G134 fit the seal, open side of the
seal leading, until the face of the seal is 1 mm
(0.039 in) below the surface of the boss.
16.Lubricate a new needle roller bearing and drive
or press the bearing into its recess until contact
is made with the shoulder at the bottom of the
bore.
17.Fit the snap ring to retain the bearing.
18.Place...

BORG WARNER
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OVERHAUL 6.Check the end float of the sun gear to the
planetary set carrier by supporting the body of
the assembly on the top of a vice. Using a dial
test indicator attached to a magnetic base,
position the base on top of the assembly and
zero the indicator on the end of the sun gear
shaft, lift the shaft and check the end float. End
float should not exceed 0.83 mm (0.033 in). Fit a
new planetary set assembly if out of limits.
NOTE: If the previous inspection
instructions prove the assembly...

41TRANSFER GEARBOX
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OVERHAUL Oil pump and filter - Assemble
11.Clean the sealant from the oil pump securing
screws.
12.Prior to assembly lubricate the pump
components with clean oil.
13.Fit the plate stampedTOPto the sun gear shaft
with the wordTOPfacing the planetary
assembly.
14.Fit the plungers and spring noting that the flats
on the plungers must be uppermost to enable
theTOP REARplate to be fitted.
15.Compress the plungers and fit the middle
bearing plate with the wordREARuppermost.
Align the...