Land Rover Defender Workshop 1993 Rover Manual

							REAR AXLE AND FINAL DRIVE 
10. Degrease  and examine  the hub  and brake 14. Fit the new  inner  and outer  bearing cups to 
disc and if necessary  replace both or  the hub, using a suitable drift or commercial 
whichever  part 
is unserviceable.  The disc IS bearing  race driving  tool. 
attached  to the  hub  with  five bolts.  Mark 
the 
15. Fit the new  inner  bearing  cone and pack with 
relationship 
of the  hub  to the  disc if the  one of the recommended  hub greases. 
original  parts 
are to be  re-assembled. 
11. Examine  the stub  axle and in particular  check 
that  the inner  seal track 
is smooth  and free 
from  blemishes. 
12. 
If necessary  remove the six retaining bolts 
and remove  the stub  axle complete  with the 
mudshield  and joint  washer. Fitting  new oil seal-inner 
Assemble  16. Clean  the hub oil seal  housing  and ensure 
that  the seal  locating  surface is smooth  and 
13. Using a new joint washer fit the stub  axle and  the chamfer on the leading  edge is also 
mud  shield. 
Coat the threads  of the retaining  smooth and free  from  burrs. 
bolts  with 
Loctite 270 and tighten  evenly to  17. Examine the new  seal and ensure  that it is 
me  correct  torque (see section  06
-Torque  clean and undamaged  and that the garter 
values).  spring 
is properly located. Even a small 
scratch 
on the seal  lip could  impair  its 
efficiency. 
18. Although  the new  seal is already  pre-greased 
by 
the manufacturer,  apply one of the 
recommended  hub bearing  greases 
to the 
outside  diameter 
of the seal  before  fitting. 
taking  care not 
to damage  the lip 
Place 
the seal,  lip side  leading.  squarely on 
the hub  and  using  the 76 mm  end of seal 
replacer 
tool LST550-5  and  drift 550 or 
18G134.  drive the seal  into position.  flush 
with 
the end  face of the hub. 
19  
						

							REAR  AXLE AND FINAL DRIVE 
26. Fit the hub  inner  nut  and  using  wrench 
606435 tighten  the  adjusting  nut while slowly 
revolving  the hub  until  all  end-float IS 
removed. then back-off  the  nut approximately 
half  a  turn and retighten  the  nut 
to 13-15 in Ib 
which will  automatically  allow for  Compression 
of  the  rubber  on the  new  seal  track spacer 
giving  the required  hub end
-float of 0.013 to 
0.10 mm (0.0005 to 0.004 in). 
27. If the  rubber  on the  seal  track  spacer  has 
previously  been  compressed the hub 
end
-float  can be checked by mounting  a dial 
indicator  and bracket  on the  hub 
so that  the 
trace  pin  rests  in a  preloaded  condition on the 
nut.  Rotate  the hub  to settle  the  bearings  and 
check  the  end
-float by pushing  and pulling  the 
hub.  End
-float must  fall within  the limits  given 
in  the  previous instruction. 
28. Fit  a new  lock  washer  and  locknut. 
Restraining  the inner  adjustment  nut,  tighten 
the  outer  lock  nut 
to 70 to 80 ft Ib (95 to 108 
Nm). 
29. If  original components  have been  refitted 
rotate  the hub  several  times to settle  the 
bearings  then  recheck  the  end
-float, refer to 
previous  note and instruction 
27. 
Fitting 
outer oil seal 
20. Fit the  new  outer  bearing cone and pack with 
one  of the  recommended  hub greases.  Carry 
out  instructions 
16 to 18. 
21. 
Place  the  seal,  lip side leading,  squarely  on 
the  hub  and  using  the 
72 mm  end  of seal 
replacer  tool LST550
-5 and  drift 550 or 
18G134, drive  the  seal  into position to the 
depth  determined  by the 
tool. 
22. Coat  the lips of both  seals  with one of the 
recommended  greases. This is important 
since  a dry  seal  can 
be destroyed during the 
first few revolutions of the hub. 
Fitting  hub to stub axle 
23. Select a new  seal track  spacer  and check that 
the outer  diameter is smooth and free from 
blemishes 
and that there are no burrs  on me 
chamfered  leading edge. 
Taking care  not to  damage the  seal lips fit 
the 
hub  assembly to the  stub  axle. Do not  allow 
the  weight 
of the hub to rest  even temporarily 
on  the  outer  seal 
otherwise damage  and 
distortion could  occur. Therefore hold  the hub 
clear 
of the  stub  axle until the seal track 
spacer  is 
fitted. 
25. Carefully fit the  seal  track  spacer, seal  lip 
leading. 
24 
30. Bend  one  segment  of the  lock  washer  over 
the  adjusting  nut  and  another,  diametrically 
opposite,  over the locknut  taking  care not to 
damage  the outer  seal. 
have  been fitted  with new components shaft  and  evenly  tighten the  retaining  bolts  of throughout. If original components  are being the correct  torque  (see section  06-Torque 
values) 
. refitted  instruction 27 must be followed  using the 
adjustment  nut to achieve  the required  end
-float. 
NOTE: 
Instruction  26  is applicable to  hubs  that 31. 
Using  a 
new joint washer, fit  the  hub  driving  
						

							REAR AXLE AND FINAL DRIVE 
32. Fit the  brake  caliper  and secure  with the 
retaining  bolts and tighten  to the  correct 
torque 
(see section  06-Torque  values).  Secure 
the  brake  pipes to the  axle  casing. 
33.  Fit the  road  wheels,  jack-up the vehicle, 
remove  the axle  stands,  lower the vehicle  to 
the  ground  and tighten  the road  wheel  nuts 
evenly  to the  correct  torque.  
						

							REAR AXLE AND FINAL DRIVE 
KEY   TO REAR HUB COMPONENTS                  
1. Rear  axle shaft 11. Inner  bearing  cup 
2. Joint washer 12. Inner  bearing  cone 
3. Locknut 13. Inner oil seal 
4. Lock washer 14. Mudshield 
5. Adjusting  nut 15. Stub axle 
6. Seal track  spacer 16. Stub axle joint  washer 
7. Outer oil seal 17. Brake  disc 
8. Outer bearing  cone 
9. Outer bearing  cup 
10. Hub  
						

							FRONT AXLE AND FINAL DRIVE 
OVERHAUL FRONT HUB ASSEMBLY 13. Remove  the key  washer. 
Service  tools: complete with  bearings. 
18G134/LRT-99-003  Bearing and oil seal  replacer  16. Mark,  for reassembly,  the  relationship 
18G1349/LRT-54-501  Hub oil seal replacer  between  the 
hub and brake  disc, 
if original 
RO530106/LRT-99-503  Dial gauge  bracket  hub  is 
to be 
refitted. 
17. Remove  the five  bolts  and  separate  the hub 
DISMANTLE from  the brake disc. 
14. Withdraw  the hub  and brake  disc assembly 
15.  Remove the  outer bearing. 
1. Slacken  road wheel  nuts. 
2. Jack up the  vehicle  and lower  onto  axle  stand. 
3. Remove the road wheel. 
4. Slacken  the  lock  nuts  securing  the  jump  hose 
to  the  retaining bracket. 
5. Remove  the two bolts  securing  the brake 
caliper,  see section 
70 - brake  disc renewal - 
and  whilst  withdrawing  the  caliper  from  the 
brake  disc release  the  jump  hose  from  the 
bracket. Tie  the  caliper  securely 
to one  side. 
NOTE: The  road  wheel  retaining  studs  must not 
be renewed.  Should any studs be unserviceable a 
new  hub complete  with studs  must be obtained. 
KEY TO HUB  ASSEMBLY 
1. Dust  cap. 
2. Drive  shaft circlip. 
3.  Drive  shaft  shim 
4.  Drive member. 
NOTE: Since  the  bracket  on later  vehicles is not 
open
-ended,  the  caliper  must be removed 5. Drive member  joint washer. 
completely,  which  involves  disconnecting  the 
6. Drive member  retaining bolt  (five off). 
jump hose. 7. Lock nut. 
8. Lock  washer. 
6. Lever-off the  dust cap. 9. Hub adjusting  nut. 
7.  Remove the  circlip from the drive shaft. 
10. Keyed washer. 
8. Remove  the drive  shaft shim. 11. Outer  bearing. 
9. Remove  the five  bolts  and  withdraw  the 12. Hub. 
driving  member  and joint  washer. 
13. Inner bearing. 
10.  Bend  back  the  lock washer  tab.  14.  Grease  seal. 
11.  Remove the  locknut and tab washer. 
15. Brake  disc. 
12.  Remove the  hub  adjusting 
nut.  
						

							FRONT AXLE AND FINAL DRIVE 
18. Drift-out the  grease  seal  and inner  bearing 
from  the hub  and  discard  the  seal. 
19. Drift-out the  inner  and outer  bearing  tracks. 
22. With the lip side  leading fit a new  seal to the 
hub  using  special 
tool 18G1349 grease  seal 
replacer  and drift  18G134.  Drive
-in  the seal 
so that it is recessed  4,83 to 5,33 mm below 
the  rear  face 
of the hub.  Apply  grease  liberally 
between  the seal  lips  and springs. 
23.  Assemble  the  brake disc 
to the hub  lining  up 
the  marks  made  during  dismantling.  Fit and 
tighten the five  retaining bolts  to 
65 to 80 Nm. 
24.  Grease  as 
in instruction  21 and fit the  outer 
25.  Clean the  stub axle and drive  shaft and 
fit the 
hub assembly 
to the  axle. 
26.  Fit the  key  washer. 
27. Fit the  hub  adjusting  nut and  tighten  by hand 
whilst  rotating  the  hub until  all end
-play  is 
taken  up. 
28.  Mount  a dial gauge  using bracket  RO530106 
and  rest  the  stylus 
in a  loaded  condition  on 
the  adjusting nut. 
Assemble 
20.  Clean  and  degrease  the hub  and drift-in the 
inner  and outer  bearing tracks. 
bearing  to  the  hub. 
21. Pack  the hub  inner  bearing with a grease 
recommended  in the  lubrication  chart and 
fit to 
the hub.  Use a minimum of 8,5  grams  of 
grease.  
						

							FRONT AXLE AND FINAL DRIVE 
29. Slacken off the  adjusting  nut until  an end-play OVERHAUL  STUB AXLE,  AXLE SHAFT, 
30.  Fit a new  keyed  lock  tab  washer. ASSEMBLY 
31. Fit and  tighten  the  hub  adjusting  nut  and 
of 0,1270 to 0,1016 mm is obtained. CONSTANT  VELOCITY  JOINT AND SWIVEL 
re-check  the end-play before  bending  the  lock Special tool: 18G284AAH/LRT-37-004 bush 
tab  over.  extractor 
32.  Fit a new  joint  washer 
to the  driving  member 
and 
fit the  member to the  hub  and secure  with 
the  five  bolts  tightening evenly to 60 to 70 
33.  Fit the  original  drive  shaft  shim  and  secure 1. Remove  the hub complete  as described  in the 
operation 
to overhaul  the hub  assembly 
34.  To  check  the  drive  shaft  end
-play mount  a dial  instructions 1 to 14. 
guage  using a  bracket  RO530106 and rest  the  2. 
Drain the  swivel pin housing  and refit plug. 
stylus in a  loaded condition  on  the  end 
of the 3. 
Remove  the  six bolts  retaining  the  stub axle to 
the swivel  housing. 
35.  Fit a  suitable  bolt  to  the  threaded end of the 4. Remove  the mud shield. 
5. Remove the  stub  axle and joint  washer. 
Remove  stub axle,  axle shaft  and constant 
velocity  joint 
drive shaft and using a  pair of pliers  move  the 
drive  shaft  back  and  forth  noting  the dial 
guage  reading.  The end
-play  should  be 
6. Pull-out the axle  shaft  and  constant  velocity 
joint  from  the  axle casing. 
36. If the end-play  requires  adjustment, remove 
the  circlip,  measure  the shim  thickness  and 
fit 
an appropriate  selective shim to give  the 
required end
-play. 
37. Remove  the  bolt from the  drive  shaft, fit the 
circlip  and dust  cap. 
38.  Fit  the  brake caliper  and tighten  the two  bolts 
to the correct  torque. 
39. 
Locate the jump hose in the  bracket  and 
tighten  the locknuts  or see  caution  below. 
CAUTION: If the  jump  nose  was disconnected  as 
is necessary on later  vehicles the brake  hydraulic 
system  must 
be bled. 
40. Fit the  road wheel,  remove the  axle  stand  and 
finally  tighten  the road wheel  nuts. 
41. Operate  the  footbrake  several  times to locate 
the  brake  pads  before  taking  the vehicle on 
the  road. 
Nm. 
with  the  circlip. 
drive  shaft. 
between 0,127 to 0,254 mm.  
						

							FRONT AXLE AND FINAL DRIVE 
Remove  constant  velocity joint from  axle shaft 12. Swivel  the cage  into  line with  the axis of the 
joint  and turn  it until 
two opposite  windows 
coincide with  two  lands of the joint  housing. 
7. Hold  the  axle  shaft  firmly in a soft jawed  vice 
8. Using a soft mallet  drive  the  constant velocity 13. Withdraw  the cage. 
joint  from  the shaft. 
9. Remove  the circlip  and collar  from  the  axle 
shaft. 
14. Turn the  inner  track at right  angles to the 
cage 
with two of  the  lands  opposite  the  cage 
openings  and  withdraw  the inner  race. 
15. Degrease  and examine  all components  for 
general  wear and condition. 
16. Examine  the inner  and  outer  track,  cage  balls 
and  bearing  surfaces  of the  constant  velocity 
joint  for  damage  and excessive  wear. 
17. To assemble  the constant  velocity  joint, 
reverse  the  dismantling  instructions  and 
lubricate  with a recommended 
EP oil. 
18. Check  that  the  end-float of the  assembled 
joint does  not exceed  0,64 mm. 
Dismantle  the constant  velocity joint 
10. Mark the  relative  positions of the constant 
velocity  joint inner  and outer  race  and the 
cage  for correct  reassembly. 
11. Tilt  and  swivel  the  cage  and  inner  race to 
remove the balls.  
						

							FRONT AXLE AND FINAL DRIVE 
30. Remove  the top swivel  pin  retaining bolts 
complete  with  the brake  jump  hose  bracket. 
31. Withdraw the top swivel pin and  shims. 
retrieving the  lower taper bearing. 
33. 
If the  swivel pin housing is to be renewed, 
remove  the  drain and  level  plugs and 
lock
-stop  bolt and  nut. 
Fit constant  velocity joint to axle 
19. Fit  the  collar  and a new  circlip. 
20.  Engage  the constant  velocity  joint  on  the axle 32. Remove  the  swivel  pin housing  whilst 
shaft  splines  and  using a soft  mallet,  drive  the 
joint  home. 
Remove  swivel pin bearing  housing 
34. Remove  the seven  bolts securing  the swivel 
pin  bearing  housing 
to the  axle  case  and 
remove  the housing  and  joint washer. 
35. Remove  and discard  the swivel  pin  oil  seal 
and joint  washer. 
Overhaul  swivel pin bearing  housing 
36. Prise-out  the  oil  seal from  the  back of the 
housing. 
37.  Drift
-out the  lower  swivel pin bearing  track. 
21. 
To remove  the bronze  brush and oil seal  use 38.  Press-out  the  upper swivel  pin  in Railko  bush 
housing. 
special tool 18G284AAH 
and a slide  hammer. 
Ensure  that  the  fingers of the  tool  locate 39. If worn, pitted or damaged,  renew  the 
housing. 
behind 
the bush,  not the oil seal.  Drive-out the 
40. Press-in the  lower  swivel  pin bearing  track. 
bush, 
then extract  the oil seal. 
41. Press
-in the  Railko  bush housing  ensuring 
that  the  machined  flat  is towards  the back 
of 
the  housing,  ie when  the housing  is fitted to 
the  axle,  the  flat  faces inboard. 
42.  With  the cavity  side trailing  press the  axle 
shaft  oil seal  into the housing  and grease. 
43.  Fit  the thrust  disc into  the  bottom 
of the Railko 
bush  housing  and check  that 
it is still in 
position  when  the  swivel pin is fitted. 
Renew  stub axle intermediate  oil seal  and bush 
Fit swivel  pin bearing  housing  to axle 
casing bolts  with  Loctite 270. 
45. Coat  both  sides of a joint  washer  and place  in 
position  on the  swivel  pin bearing  housing 
to 
axle  mating  face. 
46. Hang me swivel  pin  bearing  housing oil seal, 
retainer  and joint  washer  over  the back 
of the 
47.  Fit  and secure  the swivel  pin bearing  housing 
to the  axle  with the seven  bolts  tightening 
evenly 
to 65 to 80 Nm. 
22. 
Lubricate  the seal  and lip with  EP 90  oil  and  44. 
Coat  the 
swivel pin bearing housing to axle 
with  the  cavity side leading  press
-in a new 
intermediate  oil seal  using 
a suitable  tube. 
23.  Using  a suitable  block,  press  or drive
-in the 
bush  up 
to the shoulder. 
Remove  swivel pin housing 
24.  Remove  the brake  disc  shield  secured  by  one  housing. 
nut  and  bolt  at  the  bottom  front  and  one 
single bolt, behind  the shield, in the  swivel 
housing. 
25.  Disconnect  the track
-rod  end  ball joint  from 
the  housing. 
26.  Disconnect the  drag
-link ball  joint. 
27. Remove  the seven bolts securing  the  swivel 
pin  housing 
oil se
al and 
retaining plate  and 
joint  washer  and release  the  assembly from 
the  swivel  pin housing.  Note  that  whilst  the 
joint  washer  can be removed  at  this stage, the 
oil seal and retaining  plate  must remain  until 
the  swivel pin bearing housing  is removed. 
28.  Remove  the two  bolts,  complete  with the 
brake  disc shield  bracket,  securing  the  lower 
swivel  pin 
to the  housing. 
29.  Withdraw  the  lower swivel  pin and  joint 
Fit swivel  pin housing 
48.  Grease  and fit the lower  swivel  pin bearing  to 
the  bearing  housing. 
49.  Place  the  swivel  pin  housing  in position over 
the  swivel 
in bearing  housing.  
						

							FRONT AXLE AND FINAL DRIVE