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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual
Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual
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51REAR AXLE AND FINAL DRIVE 8 OVERHAUL 86.Before adjusting shim thickness, check pinion face marking and if it has a plus (+) figure, subtract that from shim thickness figure obtained in previous instruction. Alternatively if pinion has a minus (-) figure, add amount to shim thickness figure. 87.Adjust shim thickness under pinion inner cup as necessary, by amount determined in instructions 85 and 86. 88.Recheck pinion height setting instructions 82 to 84. If setting is correct, mean reading on dial gauge will agree with figure marked on pinion end face. For example, with an end face marking of +3, dial gauge reading should indicate that pinion is 0.003 in (0.0762 mm) below nominal. 89.When pinion setting is satisfactory, temporarily remove pinion outer bearing. 90.Fit a new collapsable bearing spacer, flared end outward, to drive pinion and refit outer bearing. 91.Fit pinion oil seal. 92.Fit oil seal gasket. 93.Fit pinion oil seal, lipped side first, using general purpose grease or, where available, a molybdenum disulphide based grease on seal lip, usingLRT-51-002to drift in seal. 94.Fit coupling flange and plain washer and loosely fit a new flange nut. SecureLRT-51-003to coupling flange, using slave fixings. 95.Alternately tighten flange nut and check drive pinion resistance to rotation until following figures are achieved, as applicable: A.Assemblies re-using original pinion bearings: 17,3 to 34,5 kgf cm. B.Assemblies with new pinion bearings: 34,5 to 46,0 kgf cm. 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.
REAR AXLE AND FINAL DRIVE 9 OVERHAUL Differential backlash checks 96.Pick up differential unit as left after instruction 52. 97.Fit differential unit and lever unit away from drive pinion until opposite bearing cup is seated against housing. Do not tilt unit. 98.Install a dial gauge on casing with its stylus resting on back face of crown wheel. Zero the gauge. 99.Lever differential unit to engage crown wheel teeth in full mesh with drive pinion teeth. Do not tilt unit. 100.Note total reading obtained on dial gauge. 101.From this figure subtract 0,25 mm to obtain correct crown wheel backlash when fitted. The result indicates value of shimming to be fitted between differential case and bearing cone at crown wheel side of differential. 102.Fit shim value determined in instruction 101, taking shims from pack previously determined during’Differential bearing adjustment’checks, instructions 57 to 62LRT-51-500details 1 and 2, pressLRT-99-002, andLRT-51-504. 103.Fit remaining shims from instruction 101 to opposite side of differential.LRT-51-501details 1 and 2, pressLRT-99-002, andLRT-51-504. 104.Fit differential unit with shims and bearings to axle casing, using axle compressorLRT-51-503 . 105.Remove axle compressor106.Fit bearing caps in their correct position, referring to relationship markings on caps and on axle casing. 107.Tighten bearing caps fixings to135 Nm (100 lbf/ft). 108.Mount a dial gauge on axle casing with stylus resting on a crown wheel tooth. 109.Prevent drive pinion from rotating and check crown wheel backlash which must be 0,15 to 0,27 mm. If backlash is not within specified limits, repeat differential backlash checks, instructions 96 to 102 looking for possible errors. 110.Fit differential cover and new gasket, coating both sides of gasket with Hylomar PL 32M or an equivalent non-setting sealant. Torque load for fixings is30 Nm (22 lbf/ft). 111.Reverse instructions 3 to 5 and coat threads of hub driving member bolts with Loctite’Studlock’ grade CVX and fit and tighten bolts evenly to correct torque. 112.Fit rear axle assembly to vehicleSee Repair. Rear axle. 113.Replenish differential with recommended lubricantSee LUBRICANTS, FLUIDS AND CAPACITIES, Information. Recommended lubricants and fluids. After initial axle run, check oil level and replenish as necessary to filler/level plug hole. 114.Where major running parts have been replaced during servicing, it is a recommended practice to allow axle assembly to’run in’by avoiding, where possible, heavy loads and high speeds during initial running.
51REAR AXLE AND FINAL DRIVE 10 OVERHAUL REAR HUB ASSEMBLY - 90 Service repair no - 64.15.13. 1.Remove rear hubSee Repair. Rear hub assembly. 2.Remove outer bearing. 3.Mark, for reassembly, position of hub to brake disc.4.Remove 5 bolts and separate hub from brake disc. WARNING: A maximum of two road wheel retaining studs can be renewed. Should more studs be unserviceable fit new hub with studs. 5.Remove grease seal and inner bearing from hub. 6.Remove inner and outer bearing tracks. REAR HUB COMPONENTS - 90 1.Axle shaft. 2.Axle shaft joint washer. 3.Axle shaft retaining bolt. 4.Lock nut. 5.Lock washer. 6.Hub adjusting nut. 7.Spacing washer.8.Outer bearing. 9.Hub. 10.Inner bearing. 11.Grease seal. 12.Brake disc. 13.Disc retaining bolt.
REAR AXLE AND FINAL DRIVE 11 OVERHAUL Refit 7.Clean hub and fit inner and outer bearing tracks. 8.Pack hub inner bearing with grease and fit to hub. 9.With lip side leading, fit a new seal flush with rear face of hub. Using service toolLRT-54-003 (LST137)seal replacer and drift. Apply grease between seal lips.10.Assemble brake disc to hub, line up reassembly marks. Applying Loctite 270, fit and tighten retaining bolts to73 Nm (54 lbf/ft). 11.Pack hub outer bearing with grease and fit to hub. 12.Fit rear hub assemblySee Repair. Rear hub assembly.
51REAR AXLE AND FINAL DRIVE 12 OVERHAUL REAR STUB AXLE - 90 Service repair no - 64.15.22. STUB AXLE COMPONENTS 1.Stub axle to axle casing bolt. 2.Mud shield. 3.Stub axle. 4.Stub axle joint washer. 5.Axle case.Overhaul 1.Remove hub assemblySee Repair. Rear hub assembly. 2.Remove 6 bolts from stub axle to axle casing. 3.Remove mud shield. 4.Remove stub axle and joint washer. Renew rear stub axle oil seal 5.Remove and discard oil seal. Lubricate seal and lip with EP90 oil. Using special toolLRT-51-004 (LST 138)fit new oil seal lip side trailing so that seal is flush with rear face of stub axle. Refit 6.Fit new joint washer, stub axle and mud shield bolts. Tighten bolts to65 Nm (48 lbf/ft). 7.Refit hub assemblySee Repair. Rear Hub Assembly.
REAR AXLE AND FINAL DRIVE 13 OVERHAUL REAR STUB AXLE - 110/130 Service repair no - 64.15.22 STUB AXLE COMPONENTS 1.Rear axle shaft 2.Stub axle to axle casing bolt 3.Mud shield 4.Stub axle 5.Stub axle joint washer 6.Axle caseOverhaul 1.Remove hub assemblySee REAR SUSPENSION, Repair. Rear hub bearing. 2.Remove 6 bolts from stub axle to axle casing. 3.Remove mud shield. 4.Remove stub axle and joint washer. 5.Remove rear axle shaft from axle casing. Renew rear stub axle oil seal 6.Remove and discard oil seal. Lubricate seal and lip EP90 oil. Using special toolLRT-51-004 (LST138) fit new seal lip side trailing so that seal is flush with rear face of stub axle. Refit 7.Fit new joint washer, stub axle and mud shield. Tighten bolts to65 Nm (48 lbf/ft). 8.Fit rear axle shaft, avoid damaging stub axle seal. 9.Refit hub assemblySee REAR SUSPENSION, Repair. Rear hub bearing.
54 - FRONT AXLE AND FINAL DRIVE CONTENTS Page DESCRIPTION AND OPERATION DESCRIPTION 1..................................................................................................... FAULT DIAGNOSIS FAULT DIAGNOSIS 1............................................................................................. REPAIR FRONT AXLE ASSEMBLY 1.................................................................................. OVERHAUL FRONT DIFFERENTIAL 1...................................................................................... FRONT HUB 1........................................................................................................ FRONT STUB AXLE, CONSTANT VELOCITY JOINT AND SWIVEL PIN HOUSING 3............................................................................................................
FRONT AXLE AND FINAL DRIVE 1 DESCRIPTION AND OPERATION DESCRIPTION The welded steel front axle casing houses a separate spiral bevel type differential unit, which is off-set to the right of the vehicle centre line. The differential unit drives the front wheels via the axle shafts and constant velocity joints which are totally enclosed in the spherical and swivel housings.The front wheels are pivoted on tape roller bearings at the top and bottom of the swivel housing. The wheel hubs on all axles are supported by two taper bearings and driven by drive flanges which are splined to the one piece, stub shaft/constant velocity joint. Front axle hub and swivel housing 1.Axle casing 2.Ventilation pipe 3.Axle shaft 4.Wheel studs and hub 5.Stub axle 6.Wheel bearings 7.Inner and outer hub seals 8.Axle shaft seal 9.Hub lock plate, thrust washer and nuts 10.Brake disc 11.Drive flange 12.Shim washer and circlip13.Dust cap 14.Constant velocity joint/shaft 15.Thrust collar for CV joint 16.Roller bearing 17.Spacer 18.Circlip 19.Top and bottom swivel taper bearing 20.Top and bottom swivel pins 21.Spherical housing, seal and retainer 22.Swivel housing 23.Constant velocity shaft seal