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Old 6th March 2014, 21:45   #1
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Default Service Manual: Borg Warner 45 series EDIT: Not for Indian vehicles

I am posting the service manual for Borg Warner 45 series. It contains all the information for overhaul and re-assembly and individual parts.
These transfer cases are in Safari and Scorpio (45-55,45-54).

Hope this will help restorers.
Please note this does not contain details about the electronic shift on the fly motor and ECU. Apparently, 45series can be mated with a manual shifter as well as electronic shifter.

https://www.dropbox.com/s/vhx10xyolom7wp6/45Series.pdf
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Old 7th March 2014, 15:40   #2
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Default re: Service Manual: Borg Warner 45 series EDIT: Not for Indian vehicles

Hey Tanveer, would this be the same for Tata Sierra ( I've got a 94 NA model which needs some care and attention)..

Cheers

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Old 7th March 2014, 15:48   #3
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Default re: Service Manual: Borg Warner 45 series EDIT: Not for Indian vehicles

Yes : See the details

45-54
Application: Telco
Safari, Sumo,
Sierra, crew cab
Configuration:
Part time
Low-range ratio: 2.48-1
Low range: helical planetary de-
sign
Lube system: gerotor pump
Fluid type: ATF
Dry weight: 63 lbs.
Shift pattern: 2H-4H-N-4L
Shift control: electrical, 4WH shift-
on-the-fly
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Old 9th April 2014, 10:40   #4
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Default re: Service Manual: Borg Warner 45 series EDIT: Not for Indian vehicles

4x4addict has informed me that this is a similar Borg Warner TC.
Indian vehicles have the TC from "Digvi Warner" which is different and internal parts may not match.
So this service manual should be taken as a general guide to disassembly, and is not compatible with Indian vehicles.

Unfortunately, I am unable to source the exact manual from Digvi Warner, but will try to do so!

Last edited by tsk1979 : 9th April 2014 at 10:44.
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Old 9th April 2014, 19:34   #5
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Default Re: Service Manual: Borg Warner 45 series EDIT: Not for Indian vehicles

Some key differences confirmed by Digvi-Warner official.
  • this manual was for Ford application 1985~90
  • the Transfer Case design is very different
  • the drop angle is LEFT as compared to RIGHT one used in TATA , MM (BTW TATA & Mahindra TC's are different with different part numbers)
  • shifting mechanism is different along with other internal parts
  • the Digvi-Warner 27 page manual has more details, pictures & information about opening the TC & trouble shooting (& i have it )
Rgds,
Nikhil

Note: The Digvi-Warner Manual is not available freely on web, I got it when i visited the Digvi-Warner factory in pune few years back.

Last edited by jeepster : 9th April 2014 at 19:39.
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