Range Rover Classic. Manual — part 65
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.
41
TRANSFER 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 to
46Nm
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
BORG WARNER
1
OVERHAUL
BORG WARNER GEARBOX ILLUSTRATED
ASSEMBLIES
Service repair no - 41.20.28
1. Front output housing assembly
2. Viscous unit
41
TRANSFER GEARBOX
2
OVERHAUL
1. Rear output housing and output shaft assembly
2. Transmission brake drum assembly
3. Speedometer drive pinion assembly
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