博格华纳Transfer Case Service Manual.docx

博格华纳Transfer Case Service Manual.docx

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博格华纳TransferCaseServiceManual

TransferCaseServiceManual

BW47-36ESOF

Version1.0

BorgWarnerTTS（Beijing）Co.,Ltd.

TableofContents

SECTION1.INTRODUCTIONANDDESCRIPTION

1-1.INTRODUCTION

Thismanualcontainsmaintenance,serviceandpartsinformationforthe47-36TransferCasesmanufacturedbyBorgWarnerTTS（Beijing）Co.,Ltd.

AsyouwillseeintheTableofContents,thismanualprovidesinformationformaintenance,troubleshooting,installation,removal,disassembly,cleaning,inspection,repairorreplacement,andassemblyoftransfercase.

Section7listsspecialtools.Thesetools,orequivalentarerequiredforproperdisassemblyandassemblyofthetransfercase.

TheexplodedviewillustrationsinSection8makeitpossibletoviewthecompleteassemblyinadditiontotheillustrationsintheservicesectionsrelatingtoaspecificserviceprocedure.

1-2.DESCRIPTION

TheBW47-36isatwo-speed,parttimetransfercase.Aplanetarygearsetisusedtoprovidegearreduction.PoweristransferredtothefrontwheeldrivethroughaMorseHy-Vochaindrive.Theunitoperatesinanoilbathplusanoilpumpisusedtoprovidepositivelubricationtotheplanetarygearsetandotheruppershaftcomponents.Threeselectorpositionsareprovided:

2H—Intwohighposition,onlythetworearwheelsaredrivenandthetransfercaseoperatesata1.00to1.00speedratio.

4H—Infourhighposition,allfourwheelsaredrivenata1.00to1.00speedratio.

4L—Infourlowposition,allfourwheelsaredrivenandthetransfercaseoperatesata2.48to1.00speedreductionratio.

Theelectricshifttransfercaseiscontrolledbyanelectricclutch,aspeedsensorandanelectricmotorthatdriveashiftcamwithinthecase.Aseparateelectronicshiftcontrolsystemisalsonecessary.Theclutchisusedtospinupthefrontdrivesystemandpermitshiftingfrom2Hto4Hatanyspeed.

The47-36transfercaseisusedforSUV&lighttruckapplications.

TheidentificationtagisinstalledonthetransfercaseatthelocationshowninFigure1-1.Figure1-1alsoillustratestheinformationtobefoundonthetag.

SECTION2.ON-VEHICLESERVICEANDTROUBLESHOOTING

2-1.MAINTENANCE

TheonlyperiodicmaintenancerequiredfortheBW47-36transfercaseistomaintainproperlubrication.RefertoTable2-1forrecommendedschedule.

Table2-1.LubricationSchedule

FREQUENCY

PROCEDURE

Witheachengineoilchange

Afterevery150000km（75000kmforheavyduty）

Checktransfercaselubricantlevel;

Changetransfercaselubricant.

Useonlyautomatictransmissionfluid,DexronIII,orequivalentinthetransfercase.Designatevolume:

1.5±0.05L.

2-1-1.CHECKINGLUBRICANTLEVEL

CAUTION:

Donotuseanimpactwrenchtoremoveorinstallfillordrainplugssincethiswilldamagefemalethreadsintransfercasecover.

NOTE:

Tocheckordrainthelubricant,thetransfercaseshouldbewarm.Thisisbestdoneshortlyaftershutdown.

a.Wipefilllevelplugandsurroundingareaclean.

b.Removefillplug.

c.Whentransfercaseisfull,lubricantwilljustdripoutfillplugopening.

d.Addapprovedlubricantifrequired.

e.Installfillplugandtorqueto19~30Nm.

2-1-2.CHANGINGLUBRICANT

a.Wipefillanddrainplugsandsurroundingareasclean.

b.Placesuitablecontainerundertransfercase.

c.Removedrainplug.

d.Removefillplug.

e.Allowalllubricanttodrain.

f.Installdrainplugandtorqueto19~30Nm.

g.Addapprovedlubricantthroughfillplugopeninguntillubricantjustbeginstodripbackoutofopening.

h.Installfillplugandtorqueto19~30Nm.

2-2.TROUBLESHOOTING

Intheeventofoperatingdifficulty,itisrecommendedthatthetransfercase（engine）beshutdown.Inmostcases,toaccuratelypinpointthesourceoftrouble,itmaybenecessarytoremoveanddisassemble,orpartiallydisassemble,thetransfercase.SpecificinspectionproceduresfordetailpartsofthetransfercaseareprovidedinSection4.

Table2-2liststroubleswhichmaybeencounteredalongwithpossiblecausesandremedies.

Table2-2.TroubleshootingChart

TROUBLE

POSSIBLECAUSE

REMEDY

Electricshiftproblems

Damagedordefectivecontrolconsolecomponent,electroniccontrolmodule,speedsensor,electricshiftmotor,electricclutchorinterconnectingwiring

Refertovehiclemanualfordiagnosisandtestproceduretoisolatefaultycomponentorcomponents.Replaceasrequired.

Damagedorwornshiftcam,hub,collar,forkorrailshaft

Disassembleandcheckforwornordamagedparts.Replaceasrequired.

Shiftfork,hubcollarorgearsbinding

Disassembleandcheckthatslidingpartsmovefreely.Replaceasrequired.

Nomechanicalshift（controllevermoves）

Controlleverorshiftlinkagebrokenordamaged

Replacedamagedparts.

Damagedshiftcam;brokenshiftforkassembly

Removetransfercasecoverandcheckfordamagedparts.Replacedamagedparts.

Hardmechanicalshiftorcontrolleverwillnotmoveintoposition

Improperoperation

Refertovehicleoperator’smanualforspecificoperatingsequence,ifany.

Improperorlowtransfercaselubricant

Addordrainandreplacewithproperlubricant（refertoparagraph2-1）

Shiftforkbinding

Removetransfercasecoverandcheckfordamagedparts.Replacedamagedparts.

Bindingorslidingshifthub,collarorgears

Removetransfercasecover,reachdownintotransfercaseandcheckthatslidingpartsslidefreelyonshaft.Removeandreplacedamagedparts.

Mechanicalshiftjumpsoutofengagement

Damagedorimproperlyadjustedshiftlinkage

Adjustorrepairshiftlinkage

Internalshiftpartsdamagedorexcessivelyworn

Disassembleandcheckforwornordamagedparts.Replacedamagedparts.

Shiftingforkassemblylooseonrailordamaged

Disassembleandcheckforwearordamage.Replacewornordamagedparts.

Mechanicalshiftlockedinoneposition

Damagedorimproperlyadjustedshiftlinkage

Adjustorrepairshiftlinkage.

Forklooseonrail

Removetransfercasecoverandcheckforlooseforkonrail.Replacepartsasrequired.

Wornordamagedforkassembly,includingpin,rollerandretainerassembly

Removetransfercasecoverandcheckforwornordamage.Replacedamagedparts.

Wornordamagedshiftcam,huborcollar

Disassembleandcheckforwornordamagedparts.Replacedamagedparts.

Wornordamagedgears

Disassembleandcheckforwornordamagedgears.Replacedamagedgears.

Nofrontwheeldrivewithcontrolinfourwheeldrive

Brokendrivechain

Disassemble,checkallinternalpartsfordamage,replacedrivechain.

Transfercasenoiseinallmodesofoperation

NOTE:

Makesurenoiseiscomingfromtransfercaseandnotclutch,transmission,driveshaftorothercomponents.

Improperorlowtransfercaselubricant

Addordrainandreplacewithproperlubricant（refertoparagraph2-1）.

Looseboltsorotherattachingparts

Makesureallattachingpartsaretorquedtospecifications.

Noisytransfercasebearings

Disassembleandcheckbearingsandpartsinandonwhichtheyoperateforwearordamage.Replacewornordamagedparts.

Noisygears

Disassembleandcheckforwornordamagedparts（includingspeedometergear）.Replacewornordamagedparts.

Transfercasenoisein4Hor4L

Wornordamagedsprocketsordrivechain

Disassembleandcheckforwornordamagedpartsandreplaceasrequired.

Incorrecttirepressure

Inflatealltirestomanualspecifications.

Transfercaseleakage

Crackedcase

Replacecase.

Leakagefromothercomponents

Verifytransfercaseleakage.Thoroughlyclean,operateandcheckforleaks.

Breatherclogged

Removebreatherhoseandbreatherandcleanorreplace.

Toomuchorimproperlubricant

Removefillplugtocheckforexcess,ordrainandreplace.

Looseboltsatsealingfaces

Torqueboltstospecifications.

Improperlyappliedsealant

Replaceandtorqueboltstospecifications.

Wornordamagedoilseal

Replaceoilseal.

2-3.REMOVALANDINSTALLATION

2-3-1.REMOVALOFTRANSFERCASE

Refertothevehicleservicemanualforspecificinstructionsregardingsupports,skidplates,shiftlinkage,wiringharness,speedometercableandothercomponentsrelatedtothetransfercaseinstallation.Thesemayneedtoberemovedtoprovideaccesstothetransfercase.Asuitablehoistforthevehicleandajackorstandforthetransfercasewillberequired.Thejackorstandmustbecapableofcompletelyandindependentlysupportingthetransfercase.Italsomustbeabletolower,raiseandmovethetransfercaselaterally.Proceedasfollows（seeFigure2-2）:

a.Positionvehicleoversuitablehoist.

b.Shifttransmissionintoparkorneutral.Shifttransfercaseinto2Handshutoffengine.

c.Disconnectnegativebatteryterminal.

d.Liftvehicle.

e.Placedrainpanundertransfercaseandremovetransfercasedrainandfillplugs（seeFigure2-1）

f.Disconnectallelectricalwiringand/orwiringharnessesfromtransfercase.

g.Disconnectspeedometercablefromtransfercasecover（50）.

h.Disconnectbreatherhosefromtransfercasebreatherbarb（43）.

i.Disconnectfrontdriveshaftfromtransfercasefrontoutputflange（44）.

j.Disconnectreardriveshaftfromtransfercaserearoutputflange（63）.

k.Supporttransfercasewithsuitablejackorstand.

CAUTION:

Makesuretransfercaseiscompletelysupportedbyjackorstandbeforeremovingnuts（201）attachingtransfercasetotransmission.Donotallowtransfercaseto“hang”fromtransmissionthroughsplinedshaftsordamagemayresults.

l.Removenuts（201）attachingtransfercasetotransmission.

m.Movetransfercasestraightbacktocompletelydisengagesplineoftransfercaseinputshaft（10）fromtransmission.

n.Carefullylowertransfercaseonjackorstand.

o.Removesealantusedbetweentransmissionandtransfercase.Cleansealantmaterialfrommating