Land Rover Defender Workshop 1993 Rover Manual

							FRONT AXLE AND FINAL DRIVE 
50. Coat  a joint  washer  both  sides  with  sealing 63. Fit the  stub  axle with  the  keyway  uppermost 
compound  and  place in position  on  the lower  at 
12 oclock. At this stage it is most  important 
swivel  pin. 
to ensure  that  the constant  velocity  joint 
51. Fit the  lower  pin with  lip outboard. Do not  bearing  journal engages  fully into the bronze 
secure  with bolts  at this  stage.  bush 
in the  rear 
of the  stub  axle before  the 
52.  Lubricate 
the  Railko  bush  with an EP  oil and  stub  axle  is secured  with  bolts.  Damage 
to the 
Fit  the top swivel pin with existing  shims  and fit bush can  occur if this  precaution  is  not 
grasp  the  stub  axle  with one 
hand and  with 
53. Coat  the  threads of the  lower  swivel pin  bolts  the other  pull the axle  shaft  into the  bush.  The 
with  Loctite  270 and fit, together  with  the  shaft and bush  are correctly 
engaged  when 
brake  disc shield  bracket,  and tighten to 22 to the end  of the  axle  shaft splines are  flush  with 
28 Nm.  the 
end of the stub  axle.  This condition must 
54. Tighten the  top  swivel  pin securing  bolts to  60 be  maintained  during  all ensuing  assembly 
to 70 Nm.  operations. 
55. To check  the top  swivel  pin  pre-load attach  a 64. Place the mud  shield  in position  and  secure 
spring  balance 
to the  track-rod  ball  joint bore  the stub  axle to the swivel  pin housing  with 
and  pull the balance 
to determine  the effort  the six bolts  using  Loctite  270 and  evenly 
required 
to turn  the swivel.  The resistance,  tighten to 60 to  70 Nm. 
once  the  initial inertia  has  been  overcome, 
65. To complete  the reassembly,  follow 
should  be  3,60 
to 4,50 Kg. If necessary,  instructions 25 to 41 covering  front hub 
adjust  by removing  or adding  shims 
to the top 
swivel  pin as  required. 
66. Check  that the swivel  pin housing  drain  plug 
the  securing  boIts 
and jump  hose  bracket (do  observed. To ensure  proper 
engagement 
overhaul. 
is tightly fitted  and remove  the  filler  level plug. 
67.  Inject  approximately  0,28 litres 
of 
recommended EP oil until the oil begins  to run 
out 
of the  filler  hole.  Fit  and tighten  the plug 
and  wipe  away  any surplus  oil. 
68.  Set the steering  lock
-stop  bolts to provide a 
clearance  between  the  tyre wall  and radius 
arm  in accordance with  the  dimensions  below. 
This  dimension  however,  must be set  to 
56 
mm,  irrespective of tyre  size  and type  where 
steering  gaiters are fitted. 
Tyre Size 
750x1 6 Michelin XS 
750x1 6 Avon Rangers 
750x16 (All  others) 
Dim A ± 0,25 mm 
54,00 mm 
54,00 mm 
51.00 mm 56. Liberally  apply - but  do not  pack - a 
recommended grease between the  lips of the 
swivel  oil seal  (2,5 to 4,0  grams). 
57. Secure  the oil seal  and joint  washer  with the 
retaining  plate and securing  bolts  tightening 
evenly to  7 
to 10 Nm. 
58. Fit  the track-rod and  drag  link and  secure with 
new  split  pins. 
59. Fit the  brake  disc  shield. 
60. Loosely fit the lock  stop  bolt and  nut for later 
adjustment.  The 
clearance  should  be set  to a minimum  of 20  mm 
on  vehicles 
fitted with 205R X 16 or 600 X 16 tyres. 
Fit  drive shaft and stub axle 
61. Place a new  joint  washer  in position  on  the 
swivel  pin housing 
to stub axle  mating  face. 
62. Taking  care  not to damage the axle  shaft  oil 
seals,  insert the axle  shaft,  and when  the 
differential  splines are  engaged,  push the 
ST1801M 
assembly home 
not  tighten).  
						

							FRONT AXLE AND FINAL  DRIVE 
OVERHAUL  FRONT AXLE DIFFERENTIAL 
Special  service tools 
18G1205/LRT-51-003  Flange restrainer  tool 
18G  191 Pinion  height setting  gauge 
18G191-4/LRT-54-503  Universal setting block 
18G47
-6/LRT-54-502  Pinion  head bearing 
remover/replacer 
LST106/L.R.T.-54-504  Oil seal  replacer 
RO 262757A/LRT-54-505  Extractor  for pinion 
bearing  caps 
RO 262757-1/LRT-54-506 Replacer,  use with 
RO262757A 
RO262757-2/LRT-54-507  Adaptor, tail bearing  cap 
replacer 
RO 530105/LRT-54-508  Spanner,  diff, flange  and 
carrier  bearings 
RO  530106/LRT
-99-503  Bracket  for dial  gauge 
MS47/LRT-99-002  Press 
18G2/L.R.T.-99-500  General purpose  puller 
MS103  Torque  meter  
						

							FRONT AXLE AND FINAL DRIVE  
						

							FRONT AXLE AND FINAL DRIVE  
						

							FRONT AXLE AND FINAL  DRIVE 
position.  tighten  the nut with  just sufficient  nip  to 
2. Smear the outer  diameter of the  new  seal  with  remove any backlash  between  the  crown 
a  recommended  all purpose  grease  and  with 
the  lip side  leading,  start it squarely  into the  3.  Line  up  the  centre 
of the  locking  finger lug 
pinion  nose  .housing. Using special  service  with a slot in the adjusting  nut. Fit  the  locking 
tool L.S.T. 106, drive  the  seal home to the  finger and secure  with  the  roll pin.  Fit the 
depth  determined  by the  tool.  opposite nut and  tighten,  with  the  above 
wrench,  until resistance  is felt. 
3. Lubricate  the  seal  lips with  a recommended 
axle  oil. Check  that the flange  seal  running 
surface 
is clean,  smooth  and  free from 
imperfections  that  could  damage the seal. 
Carefully  fit the  drive  flange  and secure  with 
the  washer  and nut.  Tighten  the nut to the 
4. Mount  the  pinion  height  setting  gauge, with 
correct  torque  whilst  holding  the  flange with  the magnetic  base on  the  pinion  housing 
restraining  tool 
18G 1205. If necessary  flange  and  the stylus resting  against  a crown 
continue  to tighten 
the nut  to  line up the  split  wheel  tooth.  Continue to tighten  the  nut, on 
pin hole  and fit a new  split pin. 
the carrier  side,  until a  backlash 
of 0,10  to 
0,17  mm 
is achieved. Do not slacken  the 
crown  wheel  side 
nut otherwise  the  backlash 
and  bearing  pre
-load will be  lost.  Line up the 
locking  finger lug with  a 
slot in the nut. 
Adjust crown  wheel and pinion backlash 
1. Return  the pinion  housing  to  the  vertical 
position  and lower  the crown  wheel  and 
differential  assembly into the pinion  housing. 
Lubricate  the  carrier bearings  and fit the 
tracks.  Fit the  bearing  caps 
so that the 
assembly  marks  line up and 
fit the bolts, 
finger  tight  only. 
2. Move  the crown wheel into  mesh  with  the 
pinion  and 
fit the  bearing  adjusting  nut on  the 
crown  wheel  side Using  wrench  RO 530105 
wheel and pinion.  
						

							FRONT AXLE AND FINAL DRIVE 
DISMANTLE 
It is important  that  when  dismantling  the  differential 
the relationship  of the  components  are marked 
relative 
to each  other  and to their position  in  the 
pinion  housing  and differential  carrier 
so that if 
refitted, the original  settings  are  maintained to avoid 
the  possibility  of noise  and  premature  wear of the 
overhauled 
axle. In particular bearing caps  and gears 
must  not be interchanged  and new  gears  should 
never  be matched with worn  ones. 
1. Drain the oil from  the  axle and refit and 
tighten  the  drain  plug.  Withdraw the  axle 
shafts  and  remove the  differential  assembly 
from  the vehicle.  Clean  and degrease  the 
exterior 
of the  pinion  housing  and  secure  the 
assembly  in a vice  in 
a vertical  position. 
2. Remove  the  two bearing  nut locking  fingers, 
by  driving  out the  retaining  roll pins  from  the 
6. Reposition the  pinion  housing in the  vice so 
that  the pinion  flange  nut is accessible. 
Remove  the split  pin 
from the pinion nut and 
using  special  service  tool RO 1205  or the 
reverse  end 
of RO 530105, to restrain the 
flange,  remove  the nut anticlockwise  using a 
bearing caps.  socket 
or ring  spanner. 
4. Using  special  service  tool RO 530105  or a 
suitable  alternative,  unscrew the  bearing  nuts 
anticlockwise. 
7. Withdraw  the pinion  complete  with  the pinion 
head bearing  and shims. 
8. Also, remove  the oil seal,  spacer  and pinion 
5. Lift-out the crown  wheel and differential  carrier 
assembly  together 
with the  taper  bearings  and 
tracks.  tail bearing. 
bearing caps using a suitable punch. 
3.  Mark  the  caps  in  relation  to  the  housing  and  slacken  the  four  bolts  securing  the  two  
						

							FRONT AXLE AND FINAL  DRIVE 
9. To remove  the pinion  head bearing  track use 
special  service  tool 
RO 262757A  ensuring that 
the  lower  end of the  tool  locates  in the 
two cut 
outs  in the  housing.  Using a ring  spanner  turn 
the  nut  clockwise  and  draw out the  track  and 
shim. 
11. Now  that  all  the  components  have  been 
removed  from  the  pinion housing,  the  main 
assemblies  can  now be  dismantled. 
To 
remove  the pinion  head  bearing,  secure  the 
press  tool 
M.S. 47  in the  vice.  Encircle  the 
bearing  with  the adaptor  collets 
18G 47-6 
ensuring  that  the ends of the  bearing  rollers 
locate  against  the  internal shoulder 
of the tool. 
Insert  the  assembly into the press  tool  and 
press  the  pinion 
from the bearing.  Remember 
to  hold  the  pinion  to  prevent 
it falling when 
released  from  the  bearing. 
12. Mark the  relationship of the  crown  wheel  to 
the  differential  carrier  and firmly  secure  the 
assembly 
in a soft  jawed  vice.  Remove  the 
ten 
bolts and  washers  and  withdraw the crown 
wheel  from  the carrier.  Since the bolt  threads 
are  secured  with  Loctite, 
it is possible  that 
they  will be tight  for the  entire length. 
10. Using  a suitable  drift, drive  out the  tail bearing 
track  locating  the drift 
in the  housing cut  outs.  
						

							FRONT AXLE AND FINAL DRIVE 
13. Remove the carrier  bearings  with  the general 
purpose 
tool 18G 2 or  a suitable alternative. It 
is  possible,  however, to drift-off  the  bearing 
from the  gear  housing side of the  carrier  by 
positioning  a drift  in the 
two cast  indentations 
behind the  bearing.  The bearing  on the  crown 
wheel  side can 
only by withdrawn  with a 
puller. 
17. Clean  and degrease all components  ready for 
inspection.  Clean  the threads of the crown 
wheel  bolts with a wire  brush 
to remove  the 
old locking  compound. 
14. To remove  the  differential  gears, release  one 
of the two circlips  securing  the cross  shaft 
and  push 
out the shaft. 
15. Turn  the gear  assembly 90 degrees  to enable 
the 
two planet  gears to be withdrawn  through 
the  carrier  aperture. 
16. Finally, remove  the two sun gears.  
						

							FRONT AXLE AND FINAL DRIVE 
INSPECTION 4. Carefully examine the sun  and  planet gears 
for  wear  on the  teeth  and the running  surfaces 
1. Examine  the pinion  housing  for  damage.  in contact  with the carrier.  Check also for 
Check  the machined surfaces and remove  any signs 
of over heating. 
burrs.  Check  the  carrier bearing nut  threads in 
5. Inspect all the  bearings  for  wear,  pitting, flats 
the  housing  and caps  and adjusting  nuts for  on the  rollers  and overheating. 
If the  bearings 
damage  and repair  as necessary.  Make sure  are serviceable  they can  be  refitted but 
if new 
that  the cast
-in  lubrication  passages (arrowed)  ones  are available  they  must  be renewed 
including  the passage 
to the tail bearing,  are  together  with the tracks. 
completely  clear of any  obstruction. 
2. Examine  the  machined  surfaces  of the 
differential  carrier  for damage, pitting, scores 
and  wear  and 
in particular  the  surfaces on 
which  the sun  and  planet  gears run.  Also, 
ensure  that  the four  lubrication  holes 
(arrowed)  are clear.  Any obstruction  here 
could cause  future  bearing failure. 
6. Examine the crown  wheel and pinion  for 
excessive  and abnormal  wear and  signs 
of 
over-heating.  Compare  the tooth contact on 
the  crown  wheel driving  side  with  the 
examples  illustrated below. These examples, 
however,  are for  the  rear  axle crown  wheel 
where  the pinion 
is driven  clockwise.  Tooth 
contact  for  the front axle  crown  wheel, where 
the  pinion  is driven  anticlockwise,  is the  same 
but  on the  opposite  side 
of the tooth.  The first 
example 
A shows  the marks that  should  be 
made  by a correctly  meshed  crown wheel and 
pinion.  The remaining  examples show 
incorrect tooth contact. 
3. Check  the cross  shaft for scores  and  pitting. 
Insert  the shaft  in the  carrier  to check  for 
excessive  wear.  
						

							FRONT AXLE AND FINAL DRIVE 
A.  Correct contact. 
B. 
C.  D. 
E.  Heel contact  - 
Insufficient backlash. 
Root 
contact 
- Pinion  too far in mesh. 
Peak  contact 
- Pinion  too far out of mesh. 
Toe  contact 
- Excessive backlash. 
ASSEMBLE 
Differential  carrier and crown  wheel 
1. Lubricate  the  carrier  bearing  journals  with 
clean  oil and  start  the bearing  squarely  on 
to 
one  side of the  carrier,  largest diameter 
towards  the carrier. 
It does  not  matter  which 
bearing  is fitted  first. Mount  the  carrier 
squarely  under  a suitable  press, supporting 
it 
under the  flange,  as close  as possible  to the 
journals.  Slowly press the  bearing  fully  home 
against the  carrier  shoulder. 
2. Repeat  the above  procedure to fit  the  second 
bearing. 
NOTE: The  crown  wheel and pinion  are only 
supplied  as a matched  set likewise  the sun  and 
planet  differential  gears. 
7. Finally, check the condition of the  pinion  and 
driving  flange  splines  and ensure  that the 
machined  outer  diameter 
of the  flange  is free 
from  any damage  that could destroy  a new  oil 
seal.  Check  that the  mud  deflector  is not 
damaged  or buckled 
to the  extent  that it 
cannot  deflect  mud  and water  away from the 
oil seal.