Range Rover Classic. Manual — part 70
BORG WARNER
19
OVERHAUL
Rear output housing (continued)
13. Lever off the dust shield.
14. Prise the oil seal from the housing and discard
the seal.
15. Remove the circlip retaining the bearing.
16. Drive or press the bearing from the housing.
Discard the bearing.
17. Remove any previous sealant from the housing
joint face.
18. Thoroughly clean all components with a suitable
solvent.
19. Examine the housing for damage and wear.
Renew as necessary.
Rear output housing - Assemble
20. Drive or press a new bearing into the housing
until the bearing contacts the shoulder.
21. Fit the circlip.
22. Lubricate a new oil seal. Using oil seal replacer
18G1422 fit the seal, lip side leading until it
contacts the circlip.
23. Fit the dust shield.
24. Place the ball bearing in the indent on the output
shaft, fit the speedometer drive gear to the shaft,
secure together with the circlip.
25. Press or drive the output shaft into the housing
until the shoulder of the shaft contacts the
bearing.
26. Lubricate the oil seal bearing surface of the drive
flange and fit the flange followed by a new
rubber seal. Fit the steel washer and secure the
flange to the shaft using a new nut. Tighten to
the specified torque.
27. Lubricate a new speedometer sleeve oil seal,
press the seal into the top of the sleeve.
28. Fit a new ’O’ ring to the outside of the sleeve,
push the driven gear spindle into the sleeve.
29. Lubricate the ’O’ ring and push the sleeve and
gear assembly into the housing. It may be
necessary to rotate the output shaft to ensure
that the driven gear engages with the drive gear
on the shaft.
30. Apply Dow Corning 732 or a suitable equivalent
silicone sealant to the rear output housing joint
face on the main casing. Evenly spread the
sealant on the face to ensure a good seal.
31. Fit the housing to the main casing and secure
with the six bolts tightened to the specified
torque.
Front output housing
- Dismantle and Inspection
Service tools:
18G1422 - Oil seal replacer.
18G1205 - Adjustable flange holding wrench
1. Support the viscous unit and front output
housing in a vice fitted with soft jaws gripping on
the two flats of the viscous unit.
2. Using service tool 18G1205 to restrain the drive
flange, release and remove the nyloc nut and
plain washer securing the drive flange to the
output shaft, withdraw the rubber seal. Discard
the nut and seal.
3. Remove the drive flange from the viscous unit.
Examine the flange for damage or wear
particularly the seal running surface, if the
surface is corroded or a groove has been worn
by the previous seal discard the flange.
41
TRANSFER GEARBOX
20
OVERHAUL
4. If necessary the oil catcher can be carefully
pressed from the drive flange, if either a new oil
catcher or bolts are being fitted.
5. Carefully tap the viscous unit out of the housing.
If the original unit is being refitted wipe clean
with a clean cloth.
NOTE: The viscous unit is a sealed
assembly and cannot be further
dismantled, a new unit should be fitted if
the unit is damaged or if the torque to turn is out
of limits.
6. Prise the oil seal out from the front output
housing and discard.
7. Remove the circlip retaining the bearing.
8. Drive or press the bearing from the housing and
discard.
9. Clean the housing with a suitable solvent.
10. Remove any previous sealant from the joint face
of the housing.
11. Examine the housing for damage and wear,
renew the housing if necessary.
Front output housing - Assemble
12. Drive or press a new bearing into the housing
13. Fit the circlip to retain the bearing.
14. Lubricate a new oil seal. Using oil seal replacing
tool 18G1422 fit the seal, lip side of the seal
leading until it contacts the circlip.
15. Carefully tap the original or new viscous unit into
the housing until contact is made with the face of
the bearing.
16. Lubricate the lips of the seal and fit the flange
followed by a new rubber seal; fit the steel
washer and secure the flange with a new nut.
Tighten to the specified torque.
17. Apply Dow Corning 732 or a suitable equivalent
silicone sealant to the output housing joint face
of the main casing. Evenly spread the sealant on
the face to ensure a good seal.
18. Fit the housing to the main casing and secure in
position with the eight bolts tightened evenly to
the specified torque.
19. Refit the gearbox to the vehicle.
BORG WARNER
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
Brake drum back plate to rear output housing
73
. . . . . . . . . . ...
Brake drum to drive flange
25
. . . . . . . . . . . . . . . . . . .
Centre differential (front to rear)
60
. . . . . . . . . . . . . . . . .
Drive flanges to transfer gearbox
224
. . . . . . . . . . . . . . . ..
Driven gear to centre differential
50
. . . . . . . . . . . . . . . .
Front cover to rear cover - main case
40
. . . . . . . . . . . . . .
Front output housing to main case
33
. . . . . . . . . . . . . . . .
Gearbox mounting brackets to chassis
45
. . . . . . . . . . . . . ..
Mounting bracket to gearbox
102
. . . . . . . . . . . . . . . . .
Neutral warning switch
47
. . . . . . . . . . . . . . . . . . . ...
Oil drain plug
25
. . . . . . . . . . . . . . . . . . . . . . . ..
Oil filler/level plug
25
. . . . . . . . . . . . . . . . . . . . . ...
Oil pump fixings
7
. . . . . . . . . . . . . . . . . . . . . . ..
Propeller shafts to drive flanges
46
. . . . . . . . . . . . . . . . .
Rear output housing to main case
40
. . . . . . . . . . . . . . . .
Selector lever shaft
8
. . . . . . . . . . . . . . . . . . . . . .
Selector fork operating arm
8
. . . . . . . . . . . . . . . . . . .
Torque values below are for all screws and bolts used except for those that are specified otherwise.
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
SERVICE TOOLS
ADAPTER PLATE TRANSFER BOX
Adaptor plate for removing Borg Warner transfer
gearbox. This can be manufactured locally to drawing
shown.
Material: Steel BS 1449 Grade 4 or 14.
Drill holes marked * to fit hoist used.
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