Land Rover Defender Workshop 1993 Rover Manual

							REAR AXLE AND FINAL DRIVE  
						

							REAR AXLE AND FINAL  DRIVE 
CAUTION: To prevent  permanent  damage to the 
gear  carrier  case, 
it must not be over-stretched. 
Each  flat on the  turnbuckle 
is numbered  to 20. Add  alignment  marks between  the crown 
enable 
a check  to be  made  on the  amount  wheel and the differential  case for reassembly 
turned.  The maximum  stretch permitted 
is 0,30 purposes,  then remove  the fixings  and 
mm,  equivalent  to three  flats. 
Dismantle  differential 
withdraw the crown  wheel. 
15. Ease off the adjuster  and remove  the 
spreader. 
21. 
Note the alignment  markings on the  two 
differential  casings 
to ensure correct refitting, 
then  remove  the fixings. 
22. 
Lift off the  upper  case. 16. Place  the tool  on to the  differential  casing, as  23. Withdraw  the upper differential  wheel and 
thrust  washer. 
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. 
Using axle compressor  GKN 131 
24. Lift out the  cross-shaft  and pinions. 
25.  Withdraw  the four  dished  thrust washers. 
26.  Withdraw  the lower  differential  wheel and 
thrust  washer.  
						

							REAR AXLE AND FINAL  DRIVE 
34. Withdraw  the outer  bearing  cone. 
27.  Remove  the differential  bearing cones using 
35. Extract  the pinion  inner bearing  cup and  shim 
remover  18G 47 BL  and  adaptors  1 and  2 and  washers from the casing.  Note the shim 
press  M.S. 47. 
washer thickness 
using remover  S 123  A. 
28.  Withdraw  the shim  washers  fitted between  the 
36. Extract  the pinion  outer bearing  cup from  the 
bearing  cones and the differential  casings. 
casing using remover  S 123  A. 
37.  Remove  the inner  bearing  cone from the 
pinion,  using remover  18G 47 BK  and  press 
M.S.  47. 
Remove  final drive pinion 
29. Prevent  the coupling  flange from rotating  and 
remove  the flange 
locknut and  plain  washer 
using  tool 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 collapsible  bearing 
spacer. 
33. Withdraw  the oil seal,  gasket  and oil thrower.  
						

							REAR AXLE AND FINAL DRIVE 
50. Secure the assembly  with bolts  using  Loctite 
Studlock  grade 
CVX on the  threads  and 
tighten  evenly and diametrically 
to 89 to 101 
Nm. 
51. Fit the  crown  wheel to the  differential  casing. 
Use  Loctite  Studlock  grade 
CVX on the  fixing 
bolt  threads  and  tighten  to the  correct  torque. 
52.  Press  on  the  differential roller bearing  cones 
less  him  washers,  using 18G 134 DP, and 
leave to one side until required for instruction 
53.  Fit the bearing  cups to the  differential. 
54.  Fit  the differential unit  and  bearings  to  the 
gear carrier casing,  and rotate  unit to 
centralize  the bearings. Do not fit the bearing 
caps. 
INSPECTION 
38.  Examine  all components  for obvious  wear or 
damage. 
39.  The bearing  cones must be 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 
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 
are  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. 
44.  Examine  the differential  case to crown  wheel 
joint  face  for burrs  and damage  which could 
lead  to crown  wheel run
-out when  fitted. 
separately. 
55. Position 
a suitable  dial gauge  indicator  on the 
casing  with the stylus  registering  on the  back 
face  of the  crown  wheel. 
56. Rotate  the differential  and check  the total 
indicated  run
-out on the  crown  wheel back 
face.  This must  not exceed  0,05 mm. 
If 
run-out is excessive,  check the mating  faces 
for  dirt  and  damage: 
if necessary,  select a 
new  radial  position  for the  crown  wheel.  When 
satisfactory,  continue with the following  check. 
Differential bearing adjustment 
57. Insert two levers between  the casing  and the 
differential  unit at one  side. 
ASSEMBLE 58. Move  the differential  unit fully to one  side  of 
the  casing;  do not 
tilt the  unit. 
Assemble  differential  unit 59. Rotate  the differential  unit to settle  the 
bearings,  continue to lever  the differential 
to 
the side,  then zero  the dial  gauge  indicator. 
60. 
Lever the  assembly fully to the other  side of 
the casing,  rotate the unit to settle  the 
45. 
Fit the  differential  lower wheel  and thrust 
washer 
to the  differential  case. See illustration 
following  instruction  23. 
46. Fit the  dished  thrust washers.  bearings, then note the total indicator  reading. 47. Fit the  cross-shaft  and pinions. 48. Fit the  differential  upper wheel and thrust 
washer. 
49. Fit  the  differential  upper case lining-up the  96.  
						

							REAR AXLE AND FINAL  DRIVE 
66. Place the selected  shim washers  on to the 
inner  bearing  cup seating. 
67.  Position 
the inner  bearing  cup in the casing. 
68.  Position  the inner  bearing  replacer  18G 
11 22 
G detail 1, onto 18G 1122  and secure  with 
the  fixing  nut. 
69. Hold  still the centre screw and  turn  the 
butterfly  lever 
to draw in the  bearing  cups. 
61.  Add 0,127  mm, 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, 
0,12  mm, 0,25  mm and 
0,76 mm.  Select  the 
total  value  of shims  required. 
62.  Remove  the differential  unit and  bearings  and 
place  aside. 
Do not fit the  shim  washers  until 
the 
subsequent Differential backlash  checks 
have  been  made,  instructions 
96 to 102. 
70. Press  the inner  bearing  cone onto the drive 
pinion  using 18G 
47 BK, details  1 and  2 and 
press 
MS 47. 
71.  Position  the pinion  and bearing  in the  casing; 
omit  the collapsible  spacer at this  stage. 
72.  Fit the  outer  bearing  cone onto the pinion. 
73.  Fit the  coupling  flange and plain  washer  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 flange  locknut.  Use a spring 
balance  to obtain  a torque  resistance  of 9,25 
to  13,8  kgf cm.  to rotate  the pinion. 
Fit drive  pinion 
63. Select shim washers of the same  thickness 
value  as those  removed  from under  the pinion 
inner  cup, instruction  35, and  place  ready for 
fitting, 
64.  Position  the outer  bearing  replacer 
18G 1122 
G detail 2, and  the outer  bearing  cup en the 
press  tool 18G  1 122. 
65. Locate  the assembly  into the pinion  housing 
nose.  
						

							REAR AXLE AND FINAL DRIVE 
Drive pinion markings 81. 
Remove  the keep  disc from  the magnetized 
base 
of dial  gauge  tool 18G191 
76. Check  that the serial  number  marked on the 82. Place  the dial  gauge  and setting  gauge 
pinion  end face  matches  that marked  on the  18G191P or 18G191
-4 on  a fiat surface  and 
crown  wheel.  zero 
the dial  gauge 
stylus on to the setting 
77. The  markings  on the  end  face  adjacent  to the  gauge. 
serial  number  are 
of no significance  during 83. Position the dial  gauge  centrally  on the  pinion 
servicing.  end face 
with the stylus  registering  on the 
78. The  figure  marked  on the  end  face  opposite  to  lowest point on one  differential  bearing bore. 
the serial  number  indicates,  in thousandths of Note  the dial  gauge  deviation  from the zeroed 
an 
inch, the deviation from  nominal  required  to 
correctly set the  pinion. A pinion  marked  plus 84. Repeat  on the  other  bearing  bore. Add 
(+) 
must be  set  below  nominal,  a minus (-) together  the readings,  then halve  the sum  to 
pinion  must be set  above  nominal.  An  obtain the mean  reading.  Note whether 
the 
unmarked  pinion must be set  at nominal. 
stylus has moved  up or down from the zeroed 
setting.  setting. 
79. The 
nominal  setting dimension  is represented 
by  the  setting  gauge block 18G191P  or 
Example 1 
18G 191 -4, which  is referenced  from the pinion 
end  face 
to the bottom  radius of the Reading obtained  L H side + 0.006in 
differential  bearing bore. The latter  gauge 
IS Reading  obtained  R H side - 0.003in 
illustrated  following instruction 
85. 
Add + 0.006in 
- 0.003in 
+ 0.003in 
Divide  by 
2 (0.003in  divided by 2)= 0.0015in 
Therefore  subtract 0.0015in from the shim  thickness 
behind the pinion  inner bearing  track 
Example  2 
Reading obtained L H side + 0.006in 
Reading  obtained R H side - 0.008in 
Add 
+ 0.006in 
- 0.008in 
- 0.002in Drive  pinion  adjustment I 
80. Ensure  that the pinion  end face  is free of 
raised  burrs around  the etched  markings.  Divide 
by 
2 (0.002in  divided by 2)= 0.001in 
Therefore  add 0.001in from the  shim thickness 
behind the pinion  inner bearing track  
						

							REAR AXLE AND FINAL DRIVE 
85. Where 
the stylus  has moved  down (85a),  the  86. Before  adjusting  the shim  thickness,  check the 
amount  is equivalent 
to the  thickness of shims  pinion face marking  and if it has a plus (+) 
that  must  be removed  from under  the pinion  figure, subtract 
that from  the shim  thickness 
inner  cup 
to bring  the pinion  down to the  figure obtained  in the  previous  instruction 
nominal  position.  Where the stylus  has moved  Alternatively 
if the pinion  has a minus (-) 
up  (85b),  the amount IS equivalent to the  figure, add the amount to the shim  thickness 
additional  thickness 
of shims required to bring  figure. 
the  pinion  up 
to the nominal  position.  87. Adjust  the shim  thickness  under the pinion 
inner  cup as necessary,  by the  amount 
Illustration 
A. Using  setting  gauge 18G191P.  determined in instructions 85 and 86. 
88.  Recheck  the pinion  height  setting  instructions 
illustration  B. Using  universal  setting block 
82 to 84. If the setting  is correct,  the mean 
18G 
191 -4. This  setting  block has three  setting  reading on the  dial  gauge will agree with the 
heights  as follows:  figure 
marked  on the  pinion  end face 
For 
example,  with an end  face  marking  of +3,  the 
39.50  mm Rationalised 
axle dial  gauge  reading  should indicate  that the 
38.10  mm Pre
-Rationalised  axle  pinion 
is 0.003  in (0.0762 mm) below  nominal. 
30.93  mm Salisbury  axle  89. When  the pinion  setting  is satisfactory, 
temporarily  remove the pinion  outer bearing. 
Ensure  that the height  marked 
30.93 mm is used for 
this  differential. 
90. Fit a new  collapsible  bearing spacer, flared 
end  outward,  to the  drive  pinion  and refit  the 
outer  bearing. 
91.  Fit the  pinion  oil slinger. 
92.  Fit the  oil seal  gasket.  
						

							REAR AXLE AND FINAL DRIVE 
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 r 
following  figures  are achieved,  as applicable: 
a.  Assemblies  re
-using  original  pinion 
bearings: 
17,3 to 34,3 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 102.  Fit  the  shim value  determined  in instruction 
101,  taking  the shims  from  the  pack 
balance,  to ensure  the correct  figures  are not previously  determined  during  Differential exceeded, otherwise a new  collapsible  bearing bearing adjustment  checks,  instructions 57 to spacer will be required. 62 18G 47 BL  details 1 and 2, using press NS 
47 and  18G  134 DP. 
103.  Fit the remaining  shims from instruction 101 to 
the  opposite side of the  differential, using 18G 
47 BL details  1  and 2, press MS 47 and  18G 
134  DP. 
104.  Fit the  differential  unit  with  shims  and 
bearings  to  the  axle casing,  using  the  axle 
spreader  18G 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 126  to 142 
Nm. 
108.  Mount  a  dial gauge 
on the axle  casing with 
the  stylus resting  on a crown  wheel tooth. 
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.  Do not  tilt the  unit. 
100.  Note  the  total  reading obtained  on the  dial 
gauge.  
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. 
101. 
From  this  figure  subtract  0.010  in  to  obtain  
						

							REAR AXLE AND FINAL DRIVE 
109. Prevent the drive  pinion  from rotating  and 
check  the crown  wheel  backlash 
which must 
be 
0,15 to  0,27  mm. 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 
112.  Fit the 
rear axle  assembly  to the  vehicle. 
113.  Replenish  the differential  lubricating oil, (see  114. Where  major running  parts have been 
Lubrication  chart). After the initial  axle run,  replaced during servicing,  it 
is a 
check  the 
oil level and replenish  as necessary  recommended practice to allow  the axle 
to the filler/level  plug hole.  assembly to run 
in by avoiding,  where 
possible,  heavy loads and high  speeds  during 
initial  running. 
DATA 
Crown  wheel backlash ........................................................... 0,15 to 0,27 mm 
Differential  bearings pre
-load ................................................. 0,127 mm 
Pinion  height setting 
............................................................... 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 turn drive  pinion  re-using the original  bearings 
OVERHAUL  REAR AXLE DIFFERENTIAL 
ASSEMBLY  DEFENDER 
90 
The differential  fitted to the  rear  axle  on Defender  90 
vehicles  is identical  to 
the differential  fitted to the 
front  axle.  For overhaul  instructions  refer to Section 
54.  34,5 
to 46  kgf  cm 
17,3 
to 34,5 kgf  cm  
						

							REAR AXLE AND FINAL DRIVE 
REAR  DISCS  REMOVE AND OVERHAUL  REAR HUBS 
Remove and refit 
Removing  MODELS 
WITH REAR  DISC BRAKES 
Service  tools: 
Oil seal  replacer  LST550-5 
Drift for  above tool MS550  or 18G134 
Hub  nut wrench  606435 
Remove 
1. Jack-up the  vehicle,  lower on to axle  stands 
and  remove  the road  wheels. 
2. Release  the brake  hose from the axle.  casing 
clips  and remove  the brake  caliper  retaining 
bolts  and secure  the  assembly 
to one side. 
Take  care  not  to kink  the  brake  hose 
3.  Remove  the five  bolts  securing  the axle  shaft 
to the hub  and  withdraw  the  shaft. 
4. Bend back the lock  tab  and  remove  the outer 
nut  using  box  wrench 
606435 and  remove - 
remove  the  lock washer.  Likewise  remove the 
inner  nut. 
5. Remove  the seal track spacer. 
6. Withdraw  the hub  complete  with  bearing oil 
seals and brake  disc. 
7. Remove the  inner and  outer  oil  seals. 
8. Remove the inner  and outer  bearing  cones 
(races). 
9. Drive-out the  inner  and  outer bearing cups. 
1. Remove the rear  hub assembly. 
2. Remove  the rear  disc fixing  bolts. 
3. Tap off the disc  from  the rear  hub. 
Refitting 
4. Locate  the disc  onto  the rear  hub. 
5. Fit the  disc  fixing  bolts.  See Section 06 for 
tightening  torques. 
6. Using  a dial  indicator,  check the  total  disc run 
out,  this  must  not exceed 
0.15 mm (0.006 in). 
If necessary  reposition the  disc. 
7. Fit the  rear  hub  assembly. 
Disc Reclamation 
Check  the  disc  thickness  marked  on the  disc 
boss
-this  dimension  may be reduced  to a  minimum 
thickness  of 13  mm  (0.510  in) front  and 12 mm 
(0.460  in) rear.  by machining  an  equal  amount off 
both sides.