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