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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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54FRONT AXLE AND FINAL DRIVE 2 DESCRIPTION AND OPERATION Lubrication The differential, swivel pin housing and wheel hubs are individually lubricated and separated by oil seals (7) and (8), see J6267A, to prevent oil transfer across the axle when the vehicle is traversing steep inclines. The wheel bearings are lubricated with grease and the swivel housing and differential with oil. On later vehicles, identified by having only a filler plug in the swivel housing, grease is used to lubricate the housing assembly, Ventilation Ventilation of the differential is through a plastic pipe (2) which terminates at a high level in the vehicle axle. The swivel housings ventilate through axle shaft oil seals (8) into the differential and the hub bearings vent via the oil seals into the swivel housing.
FRONT AXLE AND FINAL DRIVE 1 FAULT DIAGNOSIS FAULT DIAGNOSIS Complaint - Oil leaks An external leak of lubrication can be caused by a faulty internal seal. For example, if the seals which separate the differential from the swivel housings are faulty and the vehicle is operating or parked on an embankment, oil may leak across the axle leaving one swivel with a high level and the opposite swivel and differential lacking lubrication. See’Description and Operation’for illustrations of oil seal locations. When investigating leaks or checking oil levels, it is essential that all the lubrication is drained from any housing with a high level and that the other levels are checked. Swivel oil should be checked for signs of grease leaking from the hub bearings and oil contamination of the hub grease. Check that the axle ventilation system is clear, as a blockage can cause internal pressure to force oil past the seals. If the vehicle is driven in deep water with defective oil seals, water may contaminate the lubricants and when checked, give a false impression that the housing has been over filled with oil. Do not assume that a high oil level is due to over filling or, that a low level is because of an external leak.
FRONT AXLE AND FINAL DRIVE 1 REPAIR FRONT AXLE ASSEMBLY Service repair no - 54.10.01 Remove WARNING: Remove and refit of axle requires a further two persons to steady axle when lowering or repositioning axle. 1.Support chassis front. 2.Remove road wheels. 3.Support axle weight with hydraulic jack. 4.Remove radius arms to chassis frame nuts. 5.Disconnect steering damper from track rod. Using a extractor remove track rod links from swivel pin arms. 6.Remove four nuts and bolts securing radius arms to axle bracket. 7.Remove radius arms. 8.Remove bolts securing brake hose brackets . Refit bolts to prevent oil leakage. 9.Remove bolts from brake calipers and tie to one side. 10.Remove nuts and washers securing shock absorbers to axle. 11.Disconnect drag link from swivel pin housing arm. 12.Remove two nuts and bolts securing panhard rod to axle bracket. Lift rod clear of axle. 13.Mark for reassembly drive shaft flanges. Remove four nuts and bolts, tie propeller shaft to one side. 14.Release axle ventilation pipe banjo and lower axle assembly. Remove road springs. 15.Disconnect anti-roll bar linkSee FRONT SUSPENSION, Repair. Anti-roll bar ball. 16.Remove axle assembly. Refit 17.Position axle under vehicle, supporting left side of axle, and fit anti-roll bar linksSee FRONT SUSPENSION, Repair. Anti-roll bar links. 18.Fit propeller shaft. Tighten bolts to47 Nm (35 lbf/ft). 19.Fit panhard rod to axle bracket. Tighten bolts to 88 Nm (65 lbf/ft). 20.Fit drag link to swivel pin arm. Tighten fixings to 40 Nm (30 lbf/ft). 21.Fit shock absorbers to axle. 22.Fit brake calipers. Tighten bolts to82 Nm (60 lbf/ft). 23.Tighten upper swivel pin bolts to78 Nm (58 lbf/ft). 24.Fit radius arms to axle brackets. Tighten bolts to 197 Nm (145 lbf/ft). 25.Fit steering damper to track rod. 26.Fit radius arms to chassis side member. Tighten fixings to197 Nm (145 lbf/ft). 27.Tighten track rod end to40 Nm (30 lbf/ft)and fit new split pin. 28.Remove chassis supports, fit road wheels and tighten to correct torque: Alloy wheels -130 Nm (96 lbf/ft) Steel wheels -100 Nm (80 lbf/ft) Heavy duty wheels -170 Nm (125 lbf/ft)
FRONT AXLE AND FINAL DRIVE 1 OVERHAUL FRONT DIFFERENTIAL Service repair no - 54.10.07. Overhaul NOTE: The front axle differential, for all models, is the same as that fitted to the 90 rear axle and can only be serviced as a complete assemblySee REAR AXLE AND FINAL DRIVE, Repair. Differential assembly - 90.FRONT HUB Service repair no - 60.25.14. Overhaul 1.Remove hub assemblySee FRONT SUSPENSION, Repair. Front hub bearings. 2.Remove outer bearing. 3.Mark, for reassembly, relationship between hub and brake disc, if original hub is to be refitted. 4.Remove 5 bolts and separate hub from brake disc. 5.Drift out grease seal and inner bearing from hub and discard seal. 6.Drift out inner and outer bearing tracks. 7.Clean hub and drift in inner and outer bearing tracks. 8.Pack hub inner bearing with recommended grease and fit to hub.
54FRONT AXLE AND FINAL DRIVE 2 OVERHAUL 9.With lip side leading fit new seal to hub using special toolLST 137seal replacer and drift18G 134. Drive in seal flush with rear face of hub. Apply grease between seal lips. 10.Fit brake disc to hub, lining up to marks made during dismantling. Applying Loctite 270, fit retaining bolts. Tighten to73 Nm (54 lbf/ft). 11.Grease and fit outer bearing to hub. 12.Fit hub assemblySee FRONT SUSPENSION, Repair. Front hub bearings.
FRONT AXLE AND FINAL DRIVE 3 OVERHAUL FRONT STUB AXLE, CONSTANT VELOCITY JOINT AND SWIVEL PIN HOUSING Service repair no - 60.15.43. Remove stub axle, axle shaft and constant velocity joint. 1.Remove front hub assemblySee FRONT SUSPENSION, Repair. Front hub bearings. 2.Drain swivel pin housing and refit plug. NOTE: On later vehicles the swivel pin housing is filled with grease for life, the level and drain plugs being deleted. 3.Remove 6 bolts retaining stub axle to swivel housing. 4.Remove mud shield. 5.Remove stub axle and joint washer. 6.Wthdraw axle shaft and constant velocity joint from axle casing. Remove constant velocity joint from axle shaft 7.Hold axle shaft firmly in a soft jawed vice. 8.Using a soft mallet drive constant velocity joint from shaft. 9.Remove circlip and collar from axle shaft. Constant velocity joint 10.Mark positions of constant velocity joint, inner and outer race and cage for reassembly. 11.Swivel cage and inner race to remove balls.
54FRONT AXLE AND FINAL DRIVE 4 OVERHAUL 12.Examine all components, in particular, inner and outer track, cage balls and bearing surfaces for damage and excessive wear. 13.Maximum acceptable end-float on assembled joint 0,64mm. Renew if worn or damaged. Lubricate with a recommended oil during assembly. Fit constant velocity joint to axle 14.Fit collar and a new circlip. 15.Engage constant velocity joint on axle shaft splines and using a soft mallet, drive joint in fully. Renew stub axle, thrust ring, oil seal and bearing 16.Drill and chisel off thrust ring taking care to avoid damaging stub axle. 17.Remove bearing and oil seal using special tool TRT-37-004and slide hammerLRT-99-004. Ensure lip of tool locates behind bearing to to drive it out. 18.Repeat instruction for removal of oil seal. 19.Lubricate seal and lip with EP90 oil and with cavity side leading press in a new oil seal using special toolLRT-54-004. 20.Using special toolLRT-54-005, fit bearing with its part number visible when fitted, and flush with end face of stub axle. 21.Press fit a new thrust ring onto stub axle.
FRONT AXLE AND FINAL DRIVE 5 OVERHAUL Swivel pin housing 22.Remove bolts securing oil seal retaining plate and joint washer. Release assembly from swivel pin housing. NOTE: Removal of oil seal and retaining plate is achieved when swivel bearing housing is removed. 23.Remove 2 bolts, retaining lower swivel pin to housing. 24.Remove brake disc shield bracket. 25.Tap lug to remove lower swivel pin and joint washer. 26.Remove two bolts retaining brake hose bracket and top swivel pin. 27.Remove bracket, top swivel pin and shims. 28.Remove swivel pin housing while retrieving lower and upper bearings. Swivel bearing housing 29.Remove lower bearing track from swivel bearing housing. NOTE: Use upper bearing opening to gain access to lower bearing track. 30.Remove 7 bolts retaining swivel bearing housing to axle case. 31.Remove inner oil seal from back of housing. 32.Remove top bearing track from swivel bearing housing. NOTE: Use lower bearing opening to gain access to upper bearing track. 33.If worn, pitted or damaged, renew housing. 34.Fit upper and lower bearing tracks into swivel bearing housing. CAUTION: Ensure bearing tracks are fitted square or damage could occur. 35.With seal lips trailing, fit swivel housing inner oil seal into rear of housing. Grease seal lips. Fit swivel pin housing 36.Coat swivel bearing housing to axle casing bolts with Loctite 270 or equivalent. 37.Coat both sides of joint washer with a sealing compound. Position swivel bearing housing to axle mating face.Swivel assembly components 1.Swivel pin housing 2.Top swivel pin and brake hose bracket 3.Upper and lower swivel pin bearings 4.Shim 5.Retaining plate and washer 6.Oil seal 7.Joint washer 8.Swivel bearing housing 9.Joint washer 10.Lower swivel pin 11.Mudshield bracket 12.Swivel housing inner oil seal