Land Rover Defender 90 110 Workshop Book 3 Rover

							L~230T TRANSFER BOX 137 I 
./ ..... . ,L;!-: 6. Fit the 0 rings to the intermediate  shaft and into 
the  intermediate  shaft  bore  at the front  of the 
transfcr  box casing.  13. 
Turn  the  intermediate  shaft  to allow  fitting  of 
14.  Fit  retaining  plate  and  secure with retaining  bolt 
15. Fit thc intcrmediate gear shaft retaining  stake nut. 
retaining 
plate. 
and  washer. 
- .,.. .. .... ,. .. ..- , . .. I .. , . . . . . . z.. :, 
Intermediate  gear reassembly 
7. Check for damage  to the  intermcdiate shaft thread 
and 
if neccssary clean  up with  a fine  file or stone. 
8. Lubricate  the taper  roller  bearings  and 
I intermcdiate  gear shaft. 
9. Insert  new bearing  spacer  to gear  assembly, 
followed 
by the taper  roller  bearings. Adjusting  intermediate  gear torque-to-turn 
16. Select  neutral. 
17. Fit service  tool LSTlO5 to  input  gear and cngagc 
spline. 
18.  Tic  a  length of string 
to a split  pin and fit to the 
service  tool  as shown. Attach 
thc spring balance  to 
the  string. 
19. To obtain  the correct  figures and  to collapsc thc 
spacer within the intermediate gear cluster,  tighten 
the intermediate  shaft nut until  the load
-to-turn  has 
increased  by 3.7 
kg (7 Ibs) 5 1.63 kg (F 3 Ibs) on 
that  noted  when  checking  input  shaft load
-to-turn. 
The torque  to  tighten the retaining  nut will be 
ST1649M 
10. Fit dummy shaft LST104 into the intermediate gear 
cluster. 
11.  Locate  the  gear  assembly  into the transfer  box 
casing  from the bottom  cover aperture. 
12. Insert  intermediate  shaft from the front of the 
transfer  box casing,  pushing the  dummy shaft right 
through 
as shown  and  remove. (Making  sure that 
the  intermediate  gear cluster 
meshcs with the input  approximately 
203 
Nm (150 Ib ft). 
20. Peen the stake nut by carefully  forming  the  collar 
of  the  nut into  the  intermediate  shaft recess, 
as 
illustrated. ,,.. .,. :... 1 . ..;.:I . ., 
CAUTION: A round  nose tool must  be used  for this 
operation to avoid 
.,, . 
the collar of the nut. 

						

							LT230T TRANSFER BOX 
3- 
Power take-off cover - reassemble 
+- 
21.  Clean  power  take-off cover  and gasket facc. 
22. 
Fit the two  countersunk  screws and tighten. 
23.  Remove 
ihe six bolis from  the  bearing  support 
plate. 
24.  Apply sealant  to the  cover  plate  gasket  and 
fit it to 
the  bearing  support  plate. 
25.  Apply  Loctitc  290 to bolt  threads  and secure  the 
power  take
-off cover  with the six bolts  and 
washers. 
Bottom  cover - reassemble 
26. Clean bottom  cover and gasket face. 
27.  Apply  sealant  to  cover  gasket  and  fit to transfer 
28.  Apply  Loctite  290 
to bolt threads  and  secure  the 
box casing. 
bottom 
cover with six bolts and washers. 
Differential  lock switch  adjustment 
1. 
2. 
3. 
4. 
5. 
Select  differential  locked position  by moving  the 
lock  taper  towards  the right  side 
of the transfer  box 
casing. 
Apply  sealant to 
the diffcrential lock  warning light 
switch  and fit to the  top  of the  front  output 
housing. 
Connect a  test lamp  circuit  to the  differential  lock 
switch. 
Screw 
in the  lock  switch  until the bulb  is 
illuminated. 
Turn 
in the switch  another  half a turn  and  tighten 
with  the locknut  against 
the housing. 
- STl634M 
6. Disconnect  the  battery and movc the dirfercntial 
7. Clean thc front output  housing  side cover. 
8. Grcase and fit side cover gaskct. 
9. Apply  Loctite  290 to bolt  threads, fit side cover  and 
lock 
lever  to 
the left to disengage differential  lock. 
secure  with 
sevcn bolts and washers. 
Transmission  brake - reassemble 
NOTE: Under certain  circumstances  it is better to fit the 
transmission  brake assembly  after being  installed  in the 
vehicle. 
1. 
2. 
3. 
4. 
Clcan brake  backplate  and oil catcher and  apply 
sealant  to the catcher 
joint face. 
Locate  brake  backplate  on the rcar output  housing 
with  the brake  operating 
lcver on thc right side of 
the transfer  box casing. 
Secure  the backplatc  (including  the oil catcher) 
with  the four  special  bolts  and  tighten using 
21 
hexagonal socket to  the specified  torque. 
Clean  and 
fit brake drum and  secure  with two 
countersunk  screws.  
						

							PROPELLER SHAFTS 147 I 
,. .;” OVERHAUL PROPELLER  SHAFTS .. Dismantle 
1. Remove the propeller  shaft from the vehicle 
2. If a gaiter  encloses  the sliding  member  release  the 
two  securing clips.  Slide 
the gaiter  along the shaft 
to expose  the sliding  member. 
3. Note the alignment  markings on  the sliding 
member  and the propeller shaft. 
Sec note  following 
instruction 
22. 
3 
STlOOOM 
4. Unscrew the dust  cap and  withdraw  the sliding 
member. 
STlOOlM 
5. Clean  and cxamine the  splines for wear.  Worn 
splines 
or excessive  back-lash  will necessitate 
propcller shaft  renewal. 
6. Remove  paint,  rust,  etc. from  the vicinity of the 
universal  joint bearing  cups and circlips. 
NOTE: Before  dismantling  the propeller  shaft joint, 
mark  the position  of the  spider  pin lubricator  relative to 
the  journal  yoke ears to ensure  that the grease  nipple 
boss is re-assembled  in the  correct  running  position to 
reduce the possibility of imbatance. 
7. Remove  the circlips,  and grease  nipple. 
STl 00 3 M 
8. Tap the yokes  to eject  the bearing cups. 
9. Withdraw  the bearing  cups and  spider and  discard. 
10. Repeat instructions 5 to 8 at  opposite  end of 
11. Thoroughly  clean the yokcs and bearing  cup 
propeller shaft. 
locations. 
ST1004M 
ST1002 M  
						

							47 
Assemble 
12. Remove  the bearing  cups from  the new  spider. 
13.  Check  that all needle  rollers are present  and are 
properly  positioned  in the  bearing  cups. 
14. Ensure  bearing  cups are one  third  full of fresh 
lubricant.  See Lubrication  chart. 
15. Enter the new  spider  complete  with seals  into the 
yokes  of 
the sliding  member  flange. Ensure  that 
the  grease 
nipple hole  faces  away from the flange. 
16. Partially  insert one bearing  cup into  a flange  yoke 
and  enter  the spider  trunnion  into the bearing  cup 
taking  care not to dislodge  the needle  rollers. 
17. Insert  the opposite  bearing cup into  the flange 
yoke.  Using  a vice,  carefully  press both cups into 
place  taking  care to engage  the spider  trunnion 
without  dislodging  the needle  rollers. 
18. Remove  the flange  and spider  from the vice. 
19.  Using  a flat  faced  adaptor 
of slightly  smaller 
its  respective  yoke until they reach  the lower  land 
of  the  circlip  grooves. 
Do not press  the bearing 
cups  below  this point  or damage  may be caused  to 
the  cups  and seals. 
- diameter  than the bearing  cups press  each cup into 
PROPELLER SHAFTS 
rJ ST1005 M 
I- 
20. Fit the circlips. 
21.  Engage  the spider 
in the  yokes  of the  sliding 
member.  Fit the  bearing  cups and circlips  as 
described 
in instructions 15 to 20. 
22.  Lubricate  the sliding  member  spines and fit the 
sliding  member  to the  propeller  shaft ensuring  that 
the  markings  on both  the sliding  member  and 
propeller  shaft align. 
NOTE. The Universal  joints on the  front  propeller 
shaft  are, by design,  not assembled  in
-line with  one 
another.  Nevertheless,  the alignment  marks on the 
sliding  member  and propeller  shaft must coincide 
when assembling. 
23. Fit and  tighten  the dust  cap. 
24. Fit the  grease  nipples  to the  spider  and the sliding 
member  and lubricate. 
25. Slide  the gaiter  (if fitted)  over the sliding  member. 
26. Locate  the sliding  member  in the  mid-position of 
its travel  and secure  the gaiter  clips. Note that the 
gaiter  clips must  be positioned  at 
180 to each  other 
so that  they  will not influence  propeller shaft 
balance. 
26 
ST 1007M 
27.  Apply  instructions 15 to 20  to the  opposite  end of 
28. 
Fit the  grease  nipple and lubricate. 
29. 
Fit the propeller  shaft to the  vehicle. 
the 
propeller  shaft. 
ST1006M 
2  
						

							REAR DIFFERENTIAL - NINETY HEAVY DUTY -  ~~ 
OVERHAUL  REAR  AXLE  DIFFERENTIAL 7. Remove  the 
split  pin securing the pinion  flange 
(option) 8. Remove  the  pinion flange nut using service  tool 
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 removerlreplacer; 
18G 1382 oil seal replacer; 
RO 262757A extractor  for pinion  bearing  caps; 
RO 262757-1 replacer -use  with RO 262757A; 
RO 262757-2 adaptor  tail bearing  cap replacer; 
RO 530105  spanner - differential  flange and carrier 
bearing  nuts; 
RO 530106 bracket  for dial  gauge  and indicator; 
MS 47 press 
. ., I1 ye, ASSEMBLY - Land  Rover  Ninety  Heavy  Duty nut. 
18G 1205, to rcstrain the flange. 
DISMANTLE 
It is essential  that  differential  components are marked 
in their  original  positions  and relative  to  other 
components 
so that, if refitted,  their initial  setting is 
maintained.  Note  that  the bearing  caps must not be 
interchanged. 
1. Remove the  differential assembly from the axle. 
2. Drift  out  the  roll pin securing  the bearing  nut 
locking  fingers  to the  bearing  caps.  Remove  the 
locking  fingers. 
3. Slacken  the bcaring  cap bolts  and mark the caps for 
reassembly. 
4. Using  service  tool RO 530105, remove the  bearing 
adjusting nuts. 
5. Remove  the bearing  cap bolts  and bearing  caps. 
6. Lift out  the  crown  wheel,  differential  unit  and 
bearings. 
9. Withdraw  the pinion  complete  with pinion  head 
bearing  and outer  bearing  shims.  Withdraw  the 
shims. 
10. Remove  the pinion  flange oil seal,  spacer  and 
bcaring.  Discard the oil seal. 
9 
ST506M 
11. Using service tool  RO 262757A rcmove the pinion 
head  bearing  track and shim  and drift out the outer 
bearing track from  the differential  housing. 
continucd 
1  
						

							151 I REAR DIFFERENTIAL - NINETY HEAVY DUTY 
ST508M ST1202M  
18. Dismantle the pinions  and crosspin  assembly, 
noting  the relevant  positions 
of all components. 
19. If required,  extract the rollcl- bearings  and place 
them 
in thcir relative  outer tracks. 
12. 
Remove  the pinion  head bearing  with service  tool 13. For rcasscmbly purposes,  add alignment  marks to 
MS 47 and adaptor 18G 47-6. 
the crown  wheel and differcntial  case halves. 
INSPECTING WARNING: To avoid  personal  injury, the differential 
assembly  must be very  securely  retained while removing 
30. ~~~~i~~ components for obvious wear or 
the bolts  from  the crown  wheel and case  halves, as these damage. 
bolts  are Loctited  and may  be difficult to remove. 21. A11 bearings  must be press fit, except  the flange 
end  pinion  bearing,  which must be a slide 
fit on the 
A retaining  fixture can be made  from angle  iron with a shaft. 
tube and two bolts  welded to it, as illustrated, so that 22. The crown wheel and pinion are only supplied as a 
when  the fixturc is clamped  in a vice, the differential  matched set and must not be interchanged 
assembly  can be located  over the 
tubc with the fixture  separately. 
bolts  between  the case  webs. 
23. Bevel  pinion  housing  and bearing  caps are matched 
sets  and must  not 
be interchanged  separately. 
14. Remove the crown  wheel. 
24. The  differcntial  case halves  are a matched  set and 
15. Remove thc screws  holding the case halves  must not be interchanged  separately. New screws 
for securing  the case  halves  are already  coated with 
16. Withdraw  the upper  half of the casing. a dry  locking  compound and do not  require  the 
17.  Withdraw  the upper  side gear. 
Note that there  may  application of Loctite. If the old screws are being 
reused, 
thc threads  must bc cleaned  and coated 
with Loctite  ‘Studlock’  just prior to assembly. 
p:>. 
%.*. together. 
be thrust  washers  fitted to the  side  gears. 
2 
ST889M  
						

							REAR DIFFERENTIAL -NINETY HEAVY DUTY 
~2,-~; ASSEMBLY .I ,> 1- %.A NOTE: If thrust washers  were removed  from the side 
gears  during  dismantling,  the washers  must be 
lubricated  with EP90  oil and  refitted  during the 
following  procedure. 
DO NOT allow oil to contact any 
holes  or bolts  that are to be  Loctited. 
51. 
25. Position the smaller  case half with the open  side 
uppermost  and 
fit the side  gear  into the case. 
26.  Assemble  the crosspins,  pinions and  thrust 
washers,  lubricate  the thrust  washers  with 
EP90 
oil. 
27. Fit the crosspin  assembly  on to the side  gear 
already  contained 
in the differential  case  half, 
ensuring  that the gears  locate correctly. 
28. Fit the other  side gear  to  the  crosspin  assembly 
ensuring that  all the  gears  locate correctly. 
29. 
Fit the  two  case  halves  together, maintaining  the 
alignment  marking  and  ensuring  correct  gear 
mating. 
30. Fit the  correct  (high  grade) screws and tightcn 
them  evenly  to a torque 
of 3,0 to 3,7  kgf m (22 to 
27 Ibf ftj (30 to 36 Nm). 
31.  Check that  the serial  number  marked 
on thc pinion 
end  face  matches  that marked  on the  crown  wheel. 
32.  Ensure  that the differential  housing  flange  and 
crown wheel  are thoroughly clean.  Align the crown 
wheel 
with the diffcrcntial case, fit the  bolts  and 
washers  and tighten  evenly. 
33.  If removed,  press 
on the differential  roller 
bearings. 
34.  Place  the differential  housing complete  with crown 
wheel  and bearings 
in the pinion  housing. 
35. Fit the bearing caps  and bolts. Do not fully tighten 
the  bolts. 
36. 
Fit the  bearing  adjusting nuts and adjust  to obtain 
zero end
-float. 
37.  Tighten  the bearing  cap bolts. 
38.  Using  a dial  gauge  check the crown  wheel  for 
run
-out.  This  should  not  exceed 0,10 mm 
(0.004 in). If excessive  run-out is recorded  remove 
the  crown  wheel and examine  crown  wheel  and 
mounting  flange  for  burrs, grit, etc. Refit  the 
crown wheel  and  recheck.  Run
-out,  attributable  to 
a  buckled  or damaged  differential  housing  flange 
can  be  corrected  only by renewing 
the differential 
gear  housing. 
39.  When  satisfied  that run
-out is within the specified 
limits  remove  the differential  housing from 
the 
pinion  housing. 
. 
,... . .. . .,  ~ . .. , ... .I. .. I 
40. 
Remove the  crown wheel  bolts  and refit them  using 
Loctite  ‘Studlock’.  Evenly tighten the bolts  to 
5,5 
to 6,3 kgf  m (40  to 45  Ibf  ft). 
ST891M 0 
Drive  pinion 
41. Fit the pinion  head bearing  track and  the  original 
shim  to the  pinion  housing  using service  tools 
RO 262757A and RO 262757-1. If the original 
shim  was  damaged 
or mislaid use a new shim  of at 
least 1,27 mm (0.050  in) thickness. 
42. 
Fit the pinion  outer bearing  track to the  pinion 
housing 
with service  tool RO 262757A and 
RO 262757-2. 
NOTE: Instructions 41 and 42 are carried out in one 
operation 
as illustrated. 
43. Fit the  pinion  head bearing  to  the pinion  using 
continued 
service  tool 18G 47-6. 
3  
						

							REAR DIFFERENTIAL - NINETY HEAVY DUTY 
44. Enter  the  pinion  in its  location in the  pinion  51. The nominal setting dimension  is represented  by 
referenced  from the pinion  end face  to the  bottom 
radius 
of the  differential  bearing bore. 
housing. 
Do not 
fit the  shims  for bearing pre-load  the setting  gauge  block 18G 191-4  which  is 
at this stage. 
45. Fit  the  outer bearing  and spacer. 
46. Fit the driving  flange,  washer and nut. 
Drive  pinion  adjustment 
47. Do not fit the oil seal  at this stage. 
48. Tighten  the pinion  flange nut slowly until  the force 
required 
to rotate the pinion is 23  to 40,5 kgf cm 
(20  to 35  Ibf  in). This will pre-load  the bearings in 
order  to check  the pinion  height dimension. 
NOTE: If using original  bearings,  which are bedded 
in, the  pre-load figure is 11,5 to 17,25 kgf cm (10 to 
15 in Ib). 
Drive  pinion  markings 
49. The markings on the end  face  adjacent  to the serial 
number  are of no  significance  during servicing. 
50.  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 (+) must  be 
set  below  nominal, a  minus 
(-) pinion must be set 
above  nominal.  An unmarked  pinion  must  be 
sct at 
nominal. 
ST894M I I 
52.  Ensure  that the pinion  end face  is free  of raised 
burrs  around the etched markings. 
53. Remove  the keep  disc from the magnetised  base of 
dial  gauge  tool 18G  191. 
54. Place  the  dial gauge  and  setting  block on a flat 
surface  and zero the  dial gauge  stylus on the setting 
block. 
NOTE: 
The setting  block has three setting  heights 
as  follows: 
39.50 
mm Rationalised axle 
38.10 
mm Pre-Rationalised  axle 
30.93 
mm Salisbury  axle 
Ensure  that 
the height marked  39.50 mm is used 
for this  differential. 

						

							REAR DIFFERENTIAL - NINETY HEAVY DUTY 151 I 
;::-,:;: 56. Repeat on the other bearing  bore. Add together 
the  readings  then halve  the sum  to obtain  the mean 
reading.  Note whether  the stylus  has  moved up 
or 
down from  the zeroed  setting. 
a.Where the stylus  has moved  down,  the  amount is 
equivalent 
to the thickness of shims  that must  be 
removed  from  under the pinion inner track 
to bring 
the  pinion  down to the nominal  position. 
b.Where the stylus has  moved  up, the amount  is 
equivalent  to the  additional  thickness 
of shims 
required 
to bring  the  pinion up to the  nominal 
position. 
57. Before  adjusting  the  shim thickness,  check  the 
pinion  face marking and 
if it has a plus (+) figure, 
subtract  that amount  in thousandths  of an  inch 
from  the shim  thickness  fieure obtained 
in the 
.:c:. :. - .. .. ..... . .. 
- ... .  . .. 
 
previous  item. 
58. Alternatively, if the pinion  has  a minus (-) figure, 
add  the amount  to the  shim thickness  figure.  ~ 
,Adjust the 
shim  thickness  under  the pinion  head 
bearing track  as necessary. 
59. Recheck  the pinion  height setting.  If the setting is 
correct,  the mean  reading  on the  dial  gauge will 
agree  with the figure  marked  on  the  pinion  end 
face. 
For example, with an end face  marking of +3, 
the  dial  gauge  reading  should  indicate  that  the 
pinion  is 
+0.003 ins. 
Bearing  pre-load adjustment 
65. With the pinion  flange nut tightened  to a torque of 
9,6 to 16,5 kgf  m (70 to 120  Ibf ft) (95 to 163 Nm) 
the  force required to rotate the pinion  shaft should 
be  within  23 to 
40,25 kgf cm (20 to 35 lbf  ins)  when 
initial  inertia  has  been  overcome.  Change  the 
bearing  pre
-load  shim  as necessary  to obtain  this 
requirement.  A  thicker shim 
will reduce pre-load; 
a thinner  shim will increase  pre
-load. 
NOTE: If using original  bearings, which are bedded  in, 
the  pre
-load  figure  is 11,s to 17,s kgf,cm (10 to 
15 in Ib). 
66.  Remove the  pinion flange. 
67. 
Fit the oil seal  (seal  lips towards the pinion),  using 
service tool 
18G 1382 oil seal  replacer. 
ST897M 
60. Remove  the  pinion flange,  pinion,  outer bearing 
and  spacer. 
61.  Slide  new shims,  of the  same  thickness  as 
the 
originals (bearing pre-load)  into  position on the 
pinion  shaft. If the  original  shim was damaged 
or 
mislaid  use a new  shim  of at least 4,06 mm 
(0.160  in) thickness. 
62.  Enter 
the pinion in its location in the  pinion 
housing  and fit 
the outer  bearing and  spacer. 
63. Fit the driving  flange, washer  and nut. 
64. Do not fit the oil seal at this  stage.  68. 
Lubricate  the  seal lips  with 
EP90 oil. Fit the 
distance  piece and flange  and  secure 
with washer 
and nut.  Tighten 
thc nut to 9,6 to 16,5 kgf m (70 to 
120  Ibf ft) 
(95 to 163  Nm). Fit a new  split  pin. 
continucd 
.. , .,. ( . .. 
ST898M 
.: , 1. .. ST120lh 7 
5  
						

							El REAR DIFFERENTIAL - NINETY  HEAVY DUTY 
69. Place  the  differential  housing in the pinion 
70. 
Fit the  bearing  caps and bolts. Do not fully tighten 
71. 
Fit the  bearing  adjusting nuts. 
housing. 
the bolts. 
76. 
Evenly tighten the  bearing  cap bolts  torque 
77.  Recheck crown 
wheel/pinion backlash. 
78.  Lubricate  the bearings  and gears. 
* 8,3 kgf m (60 Ibf ft) (82 Nm). 
72  Using  service tool R0530105, slackcn the left  hand 
bearing  adjustment 
nut (as illustrated)  to  produce 
end  float. 
3 
I STQOOM 
73. Tighten thc right  hand nut until crown  wheel/ 
pinion  backlash  is just  removed. 
74. Tighten  the left  hand  nut slowly until the crown 
wheel/pinion backlash  is 0.10 to 0117 mm (0.004 to 
0.007 in). 
75. Fit the  locking  fingers and roll pins. If nccessary, 
tighten the adjustment  nuts slightly  to align the 
locking  finger with a slot. 
DATA 
Pinion  bearing pre-load ........................................ 
Crown  wheel run-out ........................................... 
Crown wheel/pinion backlash ................................ 
23 to 40,25 kgf cm (20 to 35 Ibf  in) 
0,10 mm (0.004 in) 
0,10 to 0,17 mm (0.004  to 0.007 in) 
6