Range Rover Classic. Manual — part 64
41
TRANSFER 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 to
46Nm
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 to
46Nm
41
TRANSFER 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)
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