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 70.............................................................................
Oil drain plug 50..............................................................................................
Breather 15.....................................................................................................
Oil level plug 30..............................................................................................
Gear change housing to extension case 25....................................................
Cover to gear change housing 10...................................................................
Bell housing to cylinder block 40.....................................................................
NOTE: Torque values below apply to all screws and bolts used unless otherwise specified.
METRIC Nm
M5 6......................................................................................................
M6 9......................................................................................................
M8 25.....................................................................................................
M10 45...................................................................................................
M12 90...................................................................................................
M14 105..................................................................................................
M16 180..................................................................................................
UNC / UNF
1/4 9......................................................................................................
5/16 24...................................................................................................
3/8 39.....................................................................................................
7/16 78...................................................................................................
1/2 90.....................................................................................................
5/8 136.................................................................................................... 
						

							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 performed by the viscous
coupling unit.Lubrication is by a low pressure plunger type oil
pump, driven by the epicyclic gear set. Oil is delivered
to the gears and bearings via oilways in the
components.
The viscous coupling though partly immersed in
lubricating oil, is a self contained and sealed unit.
Illustration RR3548M showing the component parts of
the transfer box, is a useful cross reference when
studying the following power flow diagrams.
1. Epicyclic gear set
2. Morse chain
3. Differential
4. Viscous unit/front output shaft
5. High,neutral,low selection sleeve
6. Rear output shaft 
						

							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 differential.
The maximum difference in speed permitted by the
viscous coupling must however be sufficient to allow
the vehicle to be driven on a dry road surface, in a
circle on full lock, without inducing wind up or
causing damage to the transmission.The viscous coupling has alternate plates splined to
the inner and outer members.
One set of plates is splined to 10, the outer
member/front shaft and the other plates are splined
the rear output shaft 11. The coupling is filled with a
special silicone jelly which allows sufficient slip to
occur in normal driving conditions but, which increase
the drag between the plates as the speed difference
and temperature rises, thus eliminating the need for a
manual differential lock. 
						

							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 flywheel housing.
The oil may be leaking from the gearbox
front seal, torque converter seal or the
engine crankshaft rear seal. Renew the
faulty seal.
Loss of drive - no abnormal noise from box.
1.Check that the main transmission unit is
satisfactory and confirm that loss of drive is in
the transfer box.
2.Check by feel the operation of the High/Low
transfer gear selection. Suspect failed viscous
unit.
Knocking or rattling noise in high and low ratio.
1.Check lubricant specification and level, if low do
not top up at this stage.
2.Drain lubricant and check for contamination or
metal particles.
Suspect drive chain has stretched.Abnormal noise in operation.
1.Check lubricant specification and level, if low do
not top up at this stage.
2.Drain lubricant and check for contamination or
metal particles.
Suspect oil pump failure, mechanical wear or
damage.
Transmission wind up
Transmission wind up is a build up of tension in the
transmission which will only occur if either the
differential or viscous unit is partially or completely
seized.
Vibration - harshness
1.Check operation of differential and viscous units.
Ensure that neither is partially seized.
NOTE: If both are satisfactory, but the
vibration - harshness is still present, the
alignment of the propeller shafts and
balance of the road wheels should be checked.
For balancing of road wheels.
See WHEELS AND
TYRES, Repair, Wheel Balancing
For propeller shaft alignment.See PROPELLER
SHAFTS, Description and operation, Propeller
Shaft Alignment 
						

							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 cover.
8.If necessary release circlip from drive flange to
allow new bolts to be installed.
9.Examine flange, if surface is corroded or a
groove worn by previous seal discard flange.
10.Lubricate running surface and fit flange. Do not
tighten nut.
11.Fit brake drum and secure with two screws.
Apply parkbrake and tighten drive flange nut to
224 Nm
12.Fit propeller shaft. Tighten to46Nm
FRONT OUTPUT SHAFT OIL SEAL
Service tool: 18G1422
1.Disconnect front propeller shaft from flange.
2.Apply parkbrake and release drive flange nut.
3.Remove output shaft nut, steel washer, rubber
seal and withdraw flange.
4.Prise out oil seal.
5.Lubricate and fit new seal using service tool
18G1422. Fit spring side of seal abuting circlip.
6.Examine flange if surface is corroded or worn by
previous seal discard flange.
7.Lubricate seal running surface of flange.
8.Fit flange. Tighten to
224 Nm
9.Refit propeller shaft. Tighten to46Nm 
						

							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 BODY, Repair, Centre
Console
7.Remove padding from top of transmission
tunnel.
8.Loosen pinch bolt and remove upper gear lever.
9.Remove screws and detach high low lever and
main gearlever retaining plates.Underneath vehicle
10.Drain oil from transfer gearbox.
11.Refit plug.
12.Disconnect Lambda sensor. (V8i only)
13.Remove front exhaust sections. (V8i only)
14.Remove chassis cross member secured by eight
nuts and bolts. (V8i only)
15.Mark each drive flange for reassembly and
disconnect front and rear propeller shafts from
transfer box. Tie the shafts to one side.
16.Disconnect the speed transducer multiplug.
17.Remove transmission brake drum. Remove four
bolts securing back plate to transfer box and tie
assembly aside complete with handbrake cable.
18.Remove two bolts and withdraw clutch slave
cylinder from bell housing. (Manual only) 
						

							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 hoist from rear of transfer box.
24.Remove chassis cross member. (Tdi only)
25.Remove front exhaust section. (Tdi only)
26.Lower transmission until top of transfer gearbox
clears rear floor.
27.Remove breather pipe from top of gearbox. 
						

							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 gearbox.
CAUTION: Ensure input shaft splines do
not damage oil seal in transfer gearbox.
4.Fit transfer gearbox to main gearbox with nuts
onto two studs. Fit remaining bolts.Transfer gearbox high/low link adjustment
5.Select neutral gear position.
6.Set transfer gearbox lever in a vertical position.
Rotate clevis on end of rod until hole aligns with
hole in selector lever.
7.Fit clevis pin and retaining clip. Select high and
low transfer to prove operation.
8.Reverse removal instructions, noting following
points.
9.Fit mounting bracket to gearbox. Tighten to
102
Nm
10.Fit three fixings which secure right hand
mounting bracket to chassis. Tighten to
45 Nm
11.Fit propeller shafts. Tighten to46Nm
12.Refill transfer gearbox with oil. See maintenance
schedule - check / top up transfer gearbox oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
13.Check operation of parkbrake and adjust if
necessary.
See SECTION 10, Maintenance,
Vehicle Interior