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  bearing  cone removerheplacer; 
18G 47 BL differential  bearing remover; 
18G 1122 G pinion bearing  cup replacer; 
1% 134 DP differential  bearing replacer; 
18G I91 P setting gauge for pinion height or I8G 191-4 
universal  setting block; 
18C 131 F pegs for axle  spreader; 
RO 1008 oil seal  replacer 
DISMANTLE 
NOTE: 
All fixing  bolts used on the differential  assembly 
and  differential  cover have metric  threads. 
1. Drain off thc differential  lubricating oil, and refit 
2. Remove the  rear axle assembly from the vehicle. 
3. Remove the  hub driving mcmbcr fixings. 
4.  Withdraw  the driving 
membcr and  axle  shaft 
sufficiently  to disengage the differential. 
5. Repeat  instruction 4 for the  other  axle shaft. 
6. Remove  the fixings  and  support  strip  at the 
differential  cover  and withdraw the cover  and 
joint washcr. 
7. Note the relationship  marking  on the bearing caps 
and  axle  casing  to ensure  correct  refitting. 
PI ug. 
ST639M 
Using axle spreader 18G 131 C 
9. Clean out and examine the  spreader tool pegholes 
provided in the gear casing face; ensure  that the 
holes  are free  from  dirt and 
burrs and damage. 
10. Ensure  that  the  turnbuckle  adjuster is free to 
turn. 
11. Fit the axle  spreadcr  to  engage the peg holes. 
Spreader 
18G 131 C, Adaptor  pegs 1% 131 F. 
12. Using a  spanner,  turn the adjustcr until all free 
play  between 
the spreader  and casing is takcn up, 
denoted  by the  adjuster  becoming  stiff to 
turn. 
13. Check  that  the  side members of the spreader are 
clear  of the  casing. 
14. Stretch  the casing,  rotating  the adjuster  by one 
flat  at a time, 
until the  differential  assembly can 
be  levered  out. 
Do not lever  against  the spreadcr; 
use  suitablc  packing  under the levers 
to avoid 
I 
damage  to the camg. 
CAUTION:  To prevent  permanent  damage to the 
gear  carrier  case, it must  not be over
-stretched. 
Each  flat on the  turnbuckle 
is numbered  to enable 
a check  to be  made  on the  amount  turned. The 
maximum  stretch permitted  is 
0,30 mm (0.012 in), 
equivalent  to three 
tlats. 
6 15. Ease  off the  adjuster  and remove the spreader 
ST650M 
7  
						

							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. 
19. Carefully lever-out  the differential assembly. 
ST597M 
Dismantle  differential 
20. Add  alignment marks between  the crown whccl 
and thc differential case for reasscmbly purposes, 
then 
removc the  fixings  and withdraw  the crown 
wheel. 
24. Lift out the  cross-shaft  and pinions. 
25. Withdraw thc four  dished  thrust washers. 
26.  Withdraw 
the lower  differential  wheel and thrust 
washer. 
continued 
20 
21. Note the alignment  markings on the  two e 
22. Lift off the  upper  case. 
23.  Withdraw  the upper  differentiai  wheei and thrust 
differential 
casings 
to ensure correct  refitting, 
then  remove the  fixings. 
washer. 
22 
ST652M 
8  
						

							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  cup from  the 
casing.  Remover 
S 123 A. 
Remove  final drive pinion 
29. Prevent  the coupling  flange from rotating and 
remove  the  flange  locknut  and  plain washer. 
Spanner 
18G 1205. 
30.  Support  the drive  pinion  and remove  the coupling 
flange  by tapping 
with a hide  hammer. 
31. Withdraw  the drive  pinion  together  with the inner 
bearing  cone. 
32.  Withdraw  and discard  the  collapsable  bearing 
spacer. 
33.  Withdraw the  oil seal,  gasket and 
oil thrower. 
Sl 
.... ... .. ... : .: 7. ... _. . 
37. Remove  the  inner  bearing cone  from  the pinion. 
Remover 
18G 47 RK and  Press 47. 
continued  
						

							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  pinion, if sound, 
may  be fitted  into 
a replacement  casing. 
41. 
The two  parts  of the  differential  unit casing  arc 
matched and  must not be replaced  separately. 
42.  Discard 
and renew  all thrust  washers. 
43.  Differential  housings  with  worn thrust  washer 
seatings  must be replaced as a  pair. 
face  for 
burrs and  damage  which could lead to 
crown wheel  run-out when fitted. 
- 44.- Examine the differential  case to crown  whecl joint 
ASSEMBLE 
,.. -, -. . 55. Position  a  suitablc  dial gauge  indicator on the 
casing  with 
the stylus registering  on the  back  face 
of  the  crown  wheel. 
56.  Rotate  the differcntial  and chcck  the total 
indicated 
run-out on  the  crown  wheel  back  facc. 
This  must 
not exceed 0,05 mm (0.002in). If 
run-out is excessive,  check  the mating  faces  for 
dirt  and  damage; 
if ncccssary, select a new  radial 
position  for 
the crown wheel. When satislactory, 
continue  with the following  check. 
i *- 
Assemble  differential unit Differential  bearing adjustment 
45. Fit the differential  lower wheel  and  thrust washer 
to  the  differcntial  case. Sec illustration  following 
instruction  23. 
46. Fit the dished  thrust washers. 
47. Fit the cross-shaft  and pinions. 
48. 
Fit the  differential  upper wheel and thrust  washer. 
57. Insert  two  levers  between the casing  and  the 
differential 
unit at one side. 
58. Movc the  differcntial  unit fully to one side  of the 
casing;  do not 
tilt the  unit. 
59.  Rotate  the  differential  unit  to 
scttle the bearings, 
continuc to lever  the differential to the side,  then 
60. Lever the assembly fully to the other  side of thc 
casing, rotate the unit to settle the  bearings,  then 
note 
the total  indicator  reading. 
49. Fit the differcntial  upper case lining-up the  marks. &T; zero the dial gauge indicator. . I?: 50. Secure  the assembly with bolts  using  Loctite . .. - . Studlock  grade CVX on the thrcads and tighten 
evenly  and  diametrically  to 
9,l to 10,4 kgf m (66 
to  75  Ibf 
ft). 
51. Fit thc crown wheel to the  differcntial  casing.  Use 
Loctite  Studlock 
gradc CVX on the  fixing  bolt 
threads  and tighten 
to 13 to 13,5 kgf m (95 to 
105  Ibf ft). 
52. Prcss on the differential  roller  bearing  cones  less 
shim  washers,  using 
18G 134 DP, and leave to 
one side  until  required  for instruction  96. 
continued 
53. Fit the  bearing cups  to the differential. 
54. Fit the differential unit and  bearings  to  the  gear 
carrier  casing,  and  rotate unit 
10 centralize  the 
bearings. 
Do not fit the  bearing caps. 
10  
						

							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  washers  until thc 
subsequent  ‘Differential  backlash’ checks have 
been  made,  instructions  96 to 
102. 
Fit drive  pinion 
63. Select  shim washers of the same  thickness vahe as 
those  removed  from under  the pinion  inner  cup, 
instruction 
35, and  place  ready for fitting. 
64.  Position  the 
outcr bearing rcplacer 18G 1122 G  ~ 
detail 2, and the outer 
bearing  cup on the  press 
tool 18G 1122. 
65.  Locate the  assembly into the pinion  housing nose. 
’.. . . 
v - ST661 M 
66.  Place  the selected  shim  washcrs on to the inner 
bearing 
cup seating. 
67. Position the inner bearing  cup in the casing. 
68.  Position 
the inner  bcaring  replaccr 18G 1122 G 
detail 
1, onto  18G 1122 and secure  with the fixing 
nut. 
69. 
Hold still the centre scrcw and  turn  the  butterfly 
lever  to draw 
in the  bearing  cups. 
ST662M 
70.  Press  the inner  bearing  cone onto thc drive 
71.  Position  the pinion  and bearing 
in the casing; omit 
72. 
Fit the  outer  bearing  cone onto the pinion. 
73. 
Fit the coupling  flange  and plain  washcr  and 
loosely 
fit the  flange  nut. 
74.  Tighten  the coupling  flange  locknut  to  remove 
end
-float  from the pinion. 
75. Rotate the pinion to settle  the bearings  and slowly 
tighten  the flangc  locknut. Use a  spring balancc 
to 
obtain  a  torque resistance of 9,25 to 13,8 kgf cm 
(8 to 12 Ibf in) to rotate the pinion. 
pinion. 
18G 47 BK, details 1 and 2 and 
press 47. 
the 
collapsablc spacer  at this  stage. 
continued 
I 
70% 
E 
ST638M 
11  
						

							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 (+) must  be 
set  below  nominal, a  minus 
(-) pinion  must  be  set 
above  nominal.  An unmarked  pinion  must  be 
set 
at nominal. 
ST649M 
Drive pinion  adjustment 
80. Ensure  that the pinion  end face  is free of raised 
burrs  around  the etched markings. 
81.  Remove the  keep  disc from  the 
magnctized basc 
of dial gauge  tool 18G 191. 
82. Place  the dial  gauge  and setting gauge 18G 191 P 
or 
18G 191-4 on  a  flat surface  and zero  the dial 
gauge stylus  on to the  setting  gauge. 
83. Position  the dial  gauge centrally  on the  pinion  end 
facc with  the stylus  registering  on the  lowest  point 
on  one  differential  bearing bore.  Note  the dial 
gauge  deviation  from the zeroed  setting. 
84. 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. 
- 88 
Sl 
79. The nominal  setting dimension  is represented  by 
the  setting gauge  block 
18G 191 P or 18G 191-4, 
which is referenced  from the pinion end face  to 
the  bottom  radius 
of the  differential bearing  bore. 
The  latter  gauge  is illustrated  following 
instruction 
85. 
--- ST1380M 
Example 1 
Rcading obtained L.H. sidc 
Reading obtained  R.H. side + 0.006 in if?? .r” - 0.003 in 
Add + 0.006 in 
- 0.003 in 
= + 0.003 in 
+ 0.003 = + 0.0015 in Divide by2 = - 2 
Therefore subtract 0.0015 in from the  shim thickness 
behind  the pinion  inner bearing  track. 
Example 2 
Reading obtained L.H. side + 0.006 in 
- O,()fifj iE Reading Chtained R.H. side 
Add + 0.006 in 
- 0.008 in 
= - 0.002 in 
- 0.002 Divide by2 = ____ = - O.UO1 in 2 
continued 
12  
						

							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 P. 
Illustration B. Using universal setting  block 18G 191-4 
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 30.93 mm is used  for 
this  differential. 
E3 
86. Before  adjusting  the shim  thickness, check the 
pinion  face  marking and 
if it has a plus (+) figure, 
subtract  that  amount 
in thousands  of inch  from 
the  shim  thickness figure  obtained 
in the previous 
instruction.  Alternatively 
if the  pinion  has a minus 
(-) figure,  add the amount to the  shim  thickness 
figure. 
87. Adjust the shim  thickness  under the pinion  inner 
cup  as  necessary,  by the  amount  determined 
in 
instructions 85 and 86. 
88. Recheck the pinion  height  setting  instructions 82 
to 84. If the setting  is correct, thc 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 in below  nominal. 
89.  When 
the pinion  setting  is satisfactory, 
temporarily  remove 
the pinion outer bearing. 
89 
/ 
ST646M 
ST645M 
90. Fit a new  collapsable  bcaring spdcer, flared  end 
outward,  to the  drive  pinion  and refit  the outer 
bearing. 
Fit 
the pinion  oil slinger 91 
92. Fit the oil seal gasket. 
concinucd 
ST647M 
ST644M 
13  
						

							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 
following  figures arc achieved,  as applicable: 
a.Assemblies re-using  original  pinion  bearings: 17,3 
to 34,5 kgf cm (15 to 30  Ibf  in). 
b.Assemblies with new  pinion  bearings: 343 to 
46,O kgf cm (30 to 40  Ibf  in). 
NOTE: Once  the bearing  spacer has started to 
collapse  the torque  resistance  build-up is rapid, 
therefore  check frequently,  using a spring  balance, 
to  ensure  the correct  figures are not exceeded, 
otherwise  a new  collapsable  bearing spacer  will be 
- required. 
ST643M 
Differential  backlash checks 
96. Pick  up the  differential  unit as left after 
instruction 
52. 
97.  Fit  the differential unit and  lever  the unit  away 
from  the drive  pinion  until 
the opposite  bearing 
cup  is seated  against  the housing.  Do not  tilt 
the 
unit. 
98.  Install  a dial  gauge on the casing with its stylus 
resting 
on the  back  face of the crown  wheel. Zero 
the gauge. 
99.  Lever  the differential  unit 
to engage  the crown 
wheel  teeth 
in full mesh  with the drive  pinion 
teeth. 
Dc net ti!t the unit. 
100.  Note the  total reading obtained  on the  dial  gauge. 
101.  From  this  figure  subtract 
0,25 mm (0.010 in) to 
obtain  the  correct  crown  wheel  backlash 
when 
fitted. The result  indicates  the  value of shimming 
to  be  fitted between  the differential case  and  the 
bearing  cone  at  the crown  wheel  side of the 
differential. 
14 
102. Fit the  shim  value  determined in instruction  101, 
taking 
the shims  from the pack  previously 
determined  during  ‘Differential  bearing 
adjustment’  checks,  instructions 
57 to 62 
18G 47  BL  details I and 2, prcss 47,lSG 134  DP. 
103. 
Fit the  remaining  shims  from  instruction 101 to 
the opposite  side of the  differential. 18G 47 BL 
details 
1 and 2, press  47, 18G 134 DP. 
104. Fit thc differential unit with shims  and bearings  to 
the  axle  casing,  using 
the axle spreader 1% 131 C 
with pegs 18G 131 F. 
105.  Remove the  axle spreader. 
106. 
Fit the  bearing  caps in their correct  position, 
referring  to  the relationship  markings 
on the caps 
and  on the  axle  casing. 
107.  Tighten  the bearing  caps fixings 
to 12,9 to 
14,5 kgf m (93 to 105  Ibf ft). 
108.  Mount a dial gauge  on the  axle  casing  with the 
stylus 
resting on a  crown wheel  tooth. 
continued  
						

							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  is 
2,s to 3,5 kgf m (20 to 
25 Ibf ft). 
111. Reverse  instructions 3 to 5 and coat the threads of 
the  hub  driving  member  bolts with Loctite ST640M 
‘Studlock’  grade CVX and fit and tighten the bolts 
evenly.  Torque: 
10,O kgf m (73 Ibf ft). 
112.  Fit the  rear  axle  assembly  to 
the vehicle. 
113.  Replenish 
thc differential  lubricating oil, (see 
Lubrication  chart). After the initial  axle 
run, 
check thc oil level  and replenish  as necessary  to 114. 
Where  major running  parts have been  replaced 
during  servicing, 
it is a recommended  practice to 
allow 
the axle  assembly  to ‘run  in’ by avoiding, 
where  possible,  heavy loads and high  speeds 
- the fillerAevel plug hole.  during initial running. 
DATA 
Crown  wheel backlash ......................................... 
Differential  bearings pre-load ................................ 
Pinion height setting ............................................ 
0,15 to 0,27 mm (0.006 toO.O1l in) 
0,127 
mm (0.005 in) 
Set  using  gauge 
18G 191 P or 18G 191-4 
Torque  resistance  initial setting  figures 
Torque  to turn drive  pinion and new  pinion  bearings ... 
Torque to tum drive pinion  re-using the original  bearings . 
34,5 to 46  kgf cm (30 to 40 Ibf  in) 
17,3 to 343 kgf cm (15 to 30 Ibf in) 
15  
						

							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 carrier 
bearing  nuts; 
RO 530106 bracket for dial gauge and indicator; 
MS 47 press 
DISMANTLE 
It  is essential  that differential  components  are markcd 
1 in their original  positions  and relative  to  other 
components 
so that, if refittcd, their  initial  setting  is 
maintained. 
Note that  the bcaring  caps  must not be 
interchanged. 
1. Remove  the differentlal assembly from the axle. 
2. Drift out the roll pin sccuring the bearing nut 
locking  fingers to the  bcaring  caps. Remove  the 
locking fingers. 
3. Slacken the  bearing 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 of the  crown  whecl,  differential unit and 
bearings. 
7. Remove  the split  pin securing  the  pinion flange 
ST505M / 
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 
bearing.  Discard the 
oil seal. 
ST506M 
11. Using service tool RO 262?57A, remove  the pinion 
head  bearing  track and shim  and drift  out 
thc outer 
bearing track 
from the differential  housing. 
ST 
nut. 
18G 1205 to restrain  the flange. 
8, R~~~~~ the pinion flange nut using service tool 12. Remove  the pinion  head bearing  with service tool 
MS 47 and adaptor 18G 47-6. 
16