Removal and Replacement

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 gear lever 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)

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.







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.