Service Manual: Borg Warner 45 series EDIT: Not for Indian vehicles

tsk1979 · 6th March 2014, 21:45

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

ridinthru' · 7th March 2014, 15:40

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

Cheers

RD

tsk1979 · 7th March 2014, 15:48

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

tsk1979 · 9th April 2014, 10:40

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!

jeepster · 9th April 2014, 19:34

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.

6th March 2014, 21:45	#1
tsk1979 Team-BHP Support Join Date: Feb 2005 Location: San Jose, CA Posts: 23,726 Thanked: 23,058 Times View My Garage	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
	(6) Thanks

7th March 2014, 15:40	#2
ridinthru' BANNED Join Date: Jul 2009 Location: roaming Posts: 134 Thanked: 20 Times	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 RD
	() Thanks

7th March 2014, 15:48	#3
tsk1979 Team-BHP Support Join Date: Feb 2005 Location: San Jose, CA Posts: 23,726 Thanked: 23,058 Times View My Garage	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
	(3) Thanks

9th April 2014, 10:40	#4
tsk1979 Team-BHP Support Join Date: Feb 2005 Location: San Jose, CA Posts: 23,726 Thanked: 23,058 Times View My Garage	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.
	() Thanks

9th April 2014, 19:34	#5
jeepster Senior - BHPian Join Date: Oct 2008 Location: MH24 aka LATUR Posts: 1,705 Thanked: 1,984 Times View My Garage	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.
	() Thanks