Range Rover BORG WARNER 44-62 TRANSFER BOX. Manual — part 5
TRANSFER BOX
6
OVERHAUL
INPUT SHAFT BEARING
Service repair no - 41.20.65/01
Remove
1. Remove epicyclic gear set.
See this section.
2. Remove snap ring retaining input shaft bearing
to front casing.
3. Press out input shaft bearing.
Refit
1. Clean bearing and front casing mating faces,
ensure casing is free from burrs.
2. Press bearing into front casing.
3. Fit snap ring retaining bearing to front casing.
4. Fit epicyclic gear set.
See this section.
FRONT OUTPUT SHAFT BEARING
Service repair no - 41.20.08/01
Remove
1. Remove viscous coupling unit (VCU).
See this
section.
2. Using a flat bladed screwdriver free of rough
edges, ease oil seal from VCU housing.
CAUTION: Do not mark sealing surfaces of
VCU housing.
3. Remove circlip retaining output shaft bearing to
casing.
4. Press out bearing from VCU casing.
TRANSFER BOX
OVERHAUL
7
Refit
1. Clean bearing and VCU casing mating faces.
CAUTION: Do not use a metal scraper as
this may damage sealing surfaces.
2. Press bearing into VCU housing and fit
retaining circlip.
3. Clean sealing area of VCU housing and
running surface of front output shaft drive
flange. Ensure all traces of rubber are
removed.
CAUTION: Do not use a metal scraper as
this may damage sealing surfaces.
4. Using tool LRT-41-013 , drift oil seal into VCU
housing. Ensure the seal is square to housing
bore.
5. Fit VCU to housing.
See this section.
TRANSFER BOX
8
OVERHAUL
SELECTOR FORK ASSEMBLY
Service repair no - 41.20.40/01
Remove
1. Remove viscous coupling assembly.
See this
section.
2. Remove 17 bolts securing halves of transfer
box casing.
3. Carefully break RTV seal and remove front
transfer box casing from rear casing.
4. Remove selector fork assembly, interlock spool
shaft and reduction hub from rear casing.
Collect tube spacer.
5. Remove reduction hub from selector fork
assembly.
TRANSFER BOX
OVERHAUL
9
Refit
1. Clean RTV sealant from front and rear casing
mating surfaces.
CAUTION: Do not use a metal scraper as
this may damage sealing surfaces.
2. Fit reduction hub to selector fork assembly with
hub splines towards the shorter end of shift rail.
3. Fit tube spacer to interlock spool shaft.
4. Engage selector fork cam follower to interlock
spool cam track.
5. Fit reduction hub to intermediate shaft and
engage interlock spool shaft and shift rail to
holes in rear casing.
6. Rotate interlock spool shaft to position
reduction hub and selector fork to low ratio
position, nearest rear casing half. Ensure tube
spacer is in position and selector fork cam
follower is correctly engaged in interlock spool.
7. If removed, fit 2 dowels into front casing.
8. Apply a continuous 2 mm bead of RTV sealant
to rear casing mating face. Path to be around
inside of bolt holes.
9. Fit front casing to rear casing, ensure bolt
holes and dowels are aligned before disturbing
RTV sealant.
10. Fit bolts securing front casing to rear casing
and progressively tighten to 35 Nm. (26 lbf.ft)
11. Check freedom of rotation of input shaft and
that rear output shaft rotates.
12. Fit viscous coupling assembly.
See this
section.
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