Land Rover Defender 90 110 Workshop Book 3 Rover

REAR DIFFERENTIAL - ONE TEN 151 
... . ... ., ,.. ...... ,.... .., . .., . .. ..,,A .. _, . . .,. . OVERHAUL REAR AXLE DIFFERENTIAL 
ASSEMBLY  (SALISBURY)  LAND ROVER  ONE TEN 
MODELS 8. Remove the fixings  and withdraw  the  differential 
bearing  caps. 
-, 
Service tools: 
47 screw press; 
18G 131 C axle  spreader or axle  compressor  GKN 131; 
1SG 191 dial gauge, bracket  and base; 
18G 1122 screw  press; 
18G 1205 spanner for drive coupling; 
S 123 A pinion  bearing  cup remover; 
18G 47 BK pinion...

REAR DIFFERENTIAL - ONE TEN 
Using axle compressor GKN 131 
16. Place  the  tool on to the differential  casing, as 
illustrated,  with the weld seam  uppermost. 
Ensure  that the plates  rest squarely 
on the 
differential  machined  surface  and the  end  bars 
butt  against  the edges  of the  casing. 
17. Tighten  the  adjusting  nuts  by hand  only, until all 
slack  is  taken up. 
18. Continue  to tighten  both  nuts  alternately with a 
spanner, one flat at a time, to  a maximum  of three 
flats....

REAR DIFFERENTIAL - ONE TEN 151 I 
&:>. ...+, 27. Remove  the  differential bearing cones using Ir ;.:.s;,: remover 18G 47 BL and adaptors 1 and 2 and 
press 47. 
28. Withdraw thc shim  washers  fitted  between the 
bearing  cones and the differential  casings. 
, .;:::;a ..., :>,, I..*,..” 34.  Withdraw the outer  bearing  cone. 
35.  Extract  the  pinion inner bearing  cup and  shim 
washers  from  the  casing. Note 
the shim washer 
thickness.  Remover 
S 123 A. 
36. Extract the pinion outer bearing...

151 I REAR DIFFERENTIAL- ONE TEN 
INSPECTION 
38. Examine  all components  for  obvious  wear or 
damage. 
39. 
The bearing  cones must bc a press fit on their 
locations,  except  the drive pinion  flange  and 
bearing  which is a slide  fit. 
40. The crown  wheel  and pinion  are supplied  as a 
matched  pair  and must  not  be  interchanged 
separately. 
A new crown  wheel  and pinion  matched  pair may 
be  fitted to an  original gear carrier  casing 
if sound. 
The original  crown wheel  and...

REAR DIFFERENTIAL - ONE TEN 
61. Add  0,127 mm (0.005 in),  for bearing pre-load,  to 
the  total  noted 
in the preceding  instruction.  ‘The 
sum  is then  equal  to the  nominal  value of shims 
required  for the  differential  bearings: 
Shims  are 
available in the range 0,07 mm 
(0.003  in), 0,12 mm (0.005 in), 0,25 mm 
(0.010  in) and 0,76 mm (0.030  in). Sclect the total 
value 
of shims  required. 
62.  Remove 
the differential unit and  bearings  and 
place  aside. 
Do not  fit  the shim...

151 I REAR DIFFERENTIAL - ONE TEN 
Drive pinion  markings 
76. Check  that the serial  number  marked on the 
pinion  end face  matches  that  marked  on the 
crown  wheel, 
77.  The  markings  on the  end  face  adjacent  to the 
serial  number  are 
of no  significance  during 
servicing. 
78.  The  figure  marked  on the  end  face opposite to  the 
serial  number indicates, 
in thousandths  of an inch, 
the  deviation  from nominal  required  to correctly 
set  the  pinion. 
A pinion  marked  plus...

REAR DIFFERENTIAL - ONE TEN 
..:. . .,.  , .! 85a.Where the stylus has  moved down, the amount  is . ... . I ,, ., . . ...I... equivalent to the  thickness  of shims  that must  be 
removed  from  under the pinion  inner cup  to bring 
the pinion  down to the  nominal  position. 
b.Where the sty!us has moved up,  the  amount is 
equivalent 
to the  additional  thickness  of shims 
required  to bring  the pinion  up to the  nominal 
position. 
.. .., ::: I- 
Illustration A. Using  setting  gauge 18G 191...

REAR DIFFERENTIAL - ONE TEN 
93. Fit the  pinion oil seal,  lipped  side  first, using 
general  purpose  grease 
or, where available, a 
molybdenum  disulphide based grease on the seal 
lip, using  RO 1008  to drift 
in the seal. 
94. 
Fit the  coupling  flange  and  plain washer  and 
loosely 
fit a  new  flange  nut.  Secure 18G 1205  to 
the  coupling  flange, using slave  fixings. 
95.  Alternately  tighten  the flange  nut and  check 
the 
drive  pinion  resistance  to  rotation  until the...

REAR DIFFERENTIAL - ONE TEN El 
109. Prevent  the drive  pinion  from rotating  and check 
the crown  wheel backlash  which must be 0,15 to 
0,27 mm (0.006  to 0.011  in). If the  backlash  is not 
within  the specified  limits, repeat the differential 
backlash  checks, instructions  96 to 102  looking 
for 
possible  errors. 
110. Fit the  differential  cover and new  gasket,  coating 
both  sides 
of the gasket  with Hylomar  PL 32M  or 
an  equivalent  non
-setting sealant. 
Torque  load for fixings...

REAR DIFFERENTIAL - NINETY 
FRONT  DIFFERENTIAL 
- NINETY  AND ONE TEN 
OVERHAUL AXLE DIFFERENTIAL  ASSEMBLY 
Service  tools: 
18G 1205 flange  holder  tool; 
18G 191 pinion  height  setting  gauge; 
18G 191-4 universal  setting block; 
18G 47-6 pinion  head bearing removerheplacer; 
LST 106 oil seal  replacer; or 
RO 262757A extractor for pinion  bearing  caps; 
RO 262757-1 replacer-use  with RO 262757A; 
RO 262757-2 adaptor  tail bearing  cap replacer; 
KO 530105 spanner-differential flange  and...