Borg Warner transfer case pics

**Bradtot** · 30th March 2008, 11:38 PM

This is what I did this weekend

BW transfer cases here is a pic of mine (below) from my 89 auto that has done 360k. I did not make any noises and was very quiet, I suspected that after all those kilometers the chain may be stretched and it was, also the main shaft was just ready to strip. The splines in the middle of the main chain cog have a habit of wearing thin then shearing leaving you with no drive at all.

I also had secondary clunk when I moved either the front or rear output drive flange that I was just starting to feel when I engaged drive , but could defnitley feel when moving the shafts by hand, This has turned out to be the thrust washers collapsed in the centre diff feeling as if the teeth were jumping. I had evidence of this by the amount of brass shavings attached to the pump filter pick up.(Pic 2 ) The chain had stretched so much that it was scraping the inside cover as you can see in the other pic on both the top and bottom insides.

So the BW is a great transfer case and I am very happy but like all things it does wear. I have been able to get a newer unit with a good chain but stuffed shaft so I have rebuilt that and fitted new shaft and refitted back into Rangie this weekend.

By the way the viscious unit itself is ok. I have 2 more of these cases and the other one I have after dismantling is in the same condition as mine
was, worn badly chain stretched case marked etc. There is a difference in the model 003 to the 005 and that is that the 005 has a thread for a temp sensor on the back case. I was lucky and got the one I have just fitted for nothing so it should see me for another 200k of quiet running.
I will also put this post in the tech section.

I will post some more pics later when My camera works again
sorry about pic size but at least u can zoom up for detail

Regards
Brad

**p38arover** · 30th March 2008, 11:44 PM

See here for more pics of another one (P38a) being done: RangeRovers.net :: View topic - Replaced transfer case chain with many pix

**pibby** · 22nd December 2012, 02:57 PM

putting the bloody chain back on - what tricks? mine is seriously NOT close to going back on. have just put all new bearings through.

new chain is prob 3 or 4 mm shorter when laid against old chain. meant to be an OEM, came in a britpart box saying OEM but doesn't have morse on it but aside from that it looks identical.

have lubricated it in a lite oil and 'massaged' it but just no joy. doesn't feel like stiffness is the issue, as per photo the teeth on the gear appear to be stopping it from pulling in.

any ideas?

thanks,
brett.

(ps old thread but seemed the most relevant of all the BW ones!)

**PhilipA** · 22nd December 2012, 03:05 PM

The chain looks the wrong pitch to me. Ie the link to link distance is different to the tooth to tooth distance.
Maybe someone has mixed up BW chains for another type of car. There are dozens if not hundreds of variations used in the USA.
Regards Philip A
Put the new chain and an old chain that you push together to take up wear next to each other on a table and compare, and or measure the pitch with verniers.

**justinc** · 22nd December 2012, 03:22 PM

Agree with Phillip above Brett, looks like the wrong pitch to me, too

JC

**superquag** · 22nd December 2012, 03:51 PM

Where did you get it from ?

I'd be sending them several pics and see what they say.

**pibby** · 22nd December 2012, 08:20 PM

thanks for replies.

do these photos show the pitch is wrong?

i found an 'M' on the new chain so maybe it really is a Morse after all just the darn wrong one. when i lay the chains back to back they are the same length and the links line up (as long as i squash the links back up to remove the stretch on the old chain).

the old chain is the second photo.

**PhilipA** · 23rd December 2012, 07:53 AM

You know David Ashcroft posted quite a while ago that aftermarket chains had a different angle on the chain link sides than OEM.
The pitch looks the same.
Maybe the angle on the links is preventing the chain from dropping into the teeth.
I also have one of these "M" chains, and haven't tried to fit it as ( I think it was Pibby) told me he couldn't get his to fit.

Regards Philip A

**chazza** · 23rd December 2012, 08:20 AM

Originally Posted by pibby

do these photos show the pitch is wrong?

In your first photo, it looks to me as if the pitch on the links doesn't match, the further away from the centre link, one looks. It is the first chain I have seen without the pitch stamped on the links, which makes me suspicious.

In any case the chain doesn't fit the wheel, so contact them and send it back,

Cheers Charlie

**pibby** · 23rd December 2012, 10:48 AM

sent photos to business purchased chain from. hopefully get a quick/good response. they are the ones you have to know your part numbers for and my read was they are reputable business. had to get some other parts at same time so not being a philanthropist to transport companies restricted the purchase to one business rather than ashcrofts (where i got my viscous coupling from a few weeks ago) plus the company in question.

will keep posted.

brett.

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Borg Warner transfer case pics

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