TRANSFER BOX DESCRIPTION AND OPERATION 41-3 1 Sun gear 2 Thrust washer 3 Planetary gear set assembly 4 Inner blocker ring 5 Cone 6 Detente (3 off) 7 Outer blocker ring 8 Hub - synchroniser 9 Sleeve - synchroniser 10 Outer blocker ring 11 Cone 12 Input shaft assembly 13 Main shaft 14 Thrust washer 15 Drive sprocket assembly 16 Torsen® differential assembly 17 Fork and rail assembly 18 Chain 19 Front output shaft assembly 20 Bolt (23 off) 21 Flange assembly - rear output 22 Flange O-ring 23 Flange nut 24 Actuator assembly 25 Thrust bearing (2 off) 26 Lead screw 27 Filler/level plug 28 Seal 29 Drain plug 30 Seal 31 Filter screen 32 Chip collector magnet 33 Connector tube 34 Pump feed tube 35 O-ring seal 36 Dowel (2 off) 37 Oil pump assembly 38 Rear casing assembly 39 Front output flange assembly 40 Flange O-ring 41 Flange nut 42 Mounting bush 43 Input seal 44 Retaining ring 45 Front casing assembly 46 Vent assembly 47 Pinion thrust washer (8 off) 48 Roller separator ring (12 off) 49 Pinion planet roller (144 off) 50 Planet pinion shaft (4 off) 51 Planet pinion gear (4 off)
TRANSFER BOX 41-4 DESCRIPTION AND OPERATION Transfer Box Control Diagram A = Hardwired connection C = Diagnostic DS2 bus D = CAN Bus M41 7838A A 8 6 5 3 4 2 7 11 D 9 10 1 C
TRANSFER BOX DESCRIPTION AND OPERATION 41-5 1 High/Low range selection switch 2 EAT ECU 3 Engine Control Module (ECM) 4 Actuator potentiometer 5 Actuator 6 Fuse 33 Ignition feed 7 Fusible link Permanent battery feed 8 Fuse 37 Neutral selection 9 Ignition switch 10 Diagnostic socket 11 Transfer box ECU
TRANSFER BOX 41-6 DESCRIPTION AND OPERATION Description General The NV Transfer Box is a full time, permanent four wheel drive, torque splitting transmission with equal torque distribution to the front and rear propeller shafts. The transfer box has the following features: l Permanent four wheel drive with 50/50 torque split l Two speed, fully synchronised 'shift on the move' system with electronic control and operation l High range direct drive and low range via epicyclic gearset l Torsen® Type B torque sensing and torque biasing centre differential l Self lubricating oil pump system. The transfer box is located under the vehicle in a subframe, behind the transmission. The units used on both the Td6 and V variants are identical, with the exception of the large mounting bush. The transfer box is manufactured by New Venture Gear in Roitzsch, Germany. The transfer box receives an input from the transmission output shaft which is passed through the unit to two outputs for the front and rear propeller shafts. The transfer box provides full time four wheel drive via a 50:50 torque sensing Torsen® differential. The unit design allows shift on the move from high to low range and visa versa. A planetary gearset with helical planetary pinion gears provides low range operation. When in low range, the planetary gearset provides a ratio of 2.69:1 which gives the vehicle an extremely low, low range crawl speed. High range is a direct drive from the transmission output shaft and provides a 1:1 ratio. The transfer box has electronic control, via a PWM actuator (DC motor, on the shift from high to low range. The actuator is controlled by a transfer box ECU, which is located behind the battery in the engine compartment.