Land Rover Defender Workshop Rover Manual
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TRANSFERGEARBOX 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE:Torque wrenches shouldberegularly checkedforaccuracy toensure thatallfixings are tightened tothe correct torque. Nm Transfer gearbox Pinch bolt-operating armtocrank arm 9 ...................................................... End cover gearchange housing 9 ................................................................. Bottom covertotransfer case 25 .................................................................... Front output housing totransfer case 25 ........................................................ Cross shafthousing tofront output housing 25 ............................................... Gear change housing 25 ................................................................................. Pivot shafttolink arm 25 ................................................................................. Connecting rodtoadjustable clevis 25 ........................................................... Anti-rotation plateintermediate shaft 25 ......................................................... Front output housing cover 25 ........................................................................ Pivot bracket toextension housing 25 ............................................................ Finger housing tofront output housing 25 ...................................................... Bearing housing totransfer case 25 ............................................................... Brake drumtocoupling flange 25 ................................................................... Bearing housing covertotransfer gearbox 45 ................................................ Rear output speedometer housingtotransfer gearbox 45 .............................. Selector fingertocross shafthigh/low 25 ....................................................... Selector fork,high/low toshaft 25 ................................................................... Transmission braketospeedometer housing 72 ............................................ Gate platetogrommet plate 9 ....................................................................... Gearbox totransfer case 45 ........................................................................... Oil drain plug 30 .............................................................................................. Oil filler/level plug 30 ....................................................................................... Differential case(front torear) 60 ................................................................... Output flanges 162 ........................................................................................... Differential caserearstake nut 72 .................................................................. Transfer breather 15 ....................................................................................... Transfer boxfront drive flange todrive shaft 45 .............................................. Transfer boxrear drive flange todrive shaft 45 .............................................. Transfer gearboxmounting bracketstochassis 30 ........................................ Mounting bracketstotransfer gearbox 55 ...................................................... Mounting rubberstomounting brackets 21 .....................................................
PROPELLERSHAFTS 1 DESCRIPTION ANDOPERATION PROPELLER SHAFT Description The front andrear propeller shaftshavenon-constant velocity typeuniversal joints,withneedle roller bearings. Thebearing cupsarepre-packed with lubricant onassembly andagrease nippleisfitted for servicing asspecified, inmaintenance section. Both shafts haveRilsan coated slidingsplines to accommodate thevariation indistance between the axles andtransmission. Thesplines arepre-packed with lubricant andprotected byarubber gaiter.A grease nippleisalso fitted forservicing requirements. The front shaft which isshorter thantherear is phased, withthejoints ateach end,Aand B mis-aligned asshown. The phasing isnecessary onthe front shaft onlyto allow forgreater variation inangular changes. Propeller shaft 1. Flanged yoke 2. Grease nipple 3. Journal spider 4. Needle rollerbearing 5. Circlip 6. Splined shaft 7. Rubber gaiter(dustcap) 8. Splined shaft
PROPELLERSHAFTS 1 FAULT DIAGNOSIS VIBRATION HARSHNESS Check thatthepropeller shaftuniversal jointsand sliding splines arenotsiezed orworn andthatthe shafts arecorrectly aligned. NOTE:Inthe event thatboth shafts are satisfactory, butthevibration/harshness is still present, thetransfer boxoperation and balance ofthe road wheels shouldbe checked. For transfer boxoperation See TRANSFER GEARBOX, Faultdiagnosis, TransferGearbox - Oil seal locations . For balance ofroad wheels SeeWHEELS AND TYRES, Repair, WheelBalancing.
PROPELLERSHAFTS 1 REPAIR PROPELLER SHAFT Service repairno-47.15.02/03 Remove 1. Place vehicle onramp. 2. Mark driveflanges ateach endofpropeller shaft for reassembly. 3. Remove 4bolts/nuts fromeach endandremove propeller shaft. NOTE:Achassis undertray maybefitted on some vehicle derivatives toconform to legal requirements. Whenunder chassis remove andrefit procedures arerequired, itmay be necessary toremove theundertray See CHASSIS ANDBODY, Repair, Frontundertray or SeeCHASSIS ANDBODY, Repair, Rearundertray . Service repairno-47.15.11/12 Overhaul 4. Thoroughly examineuniversal jointforsigns of damage orwear. Replace ifnecessary. 5. Clean universal jointbearing cupsandcirclips. CAUTION: Toensure correct assembly and reduce possibility ofimbalance, mark position ofspider pinlubricator relativeto journal yokeears, before removing propellershaft joint. 6. Remove circlips,andgrease nipple. 7. Tap yokes toeject bearing cups. 8. Remove bearingcupsandspider. 9. Repeat instructions 4to 7 for opposite endof propeller shaftifnecessary. 10. Clean yokes andbearing cuplocations.
47PROPELLER SHAFTS 2 REPAIR Assembly 11. Remove bearingcupsfromnewspider. 12. Check allneedle rollersarepresent and positioned inbearing cups. 13. Ensure bearing cupsareone-third fullof lubricant See LUBRICANTS, FLUIDSAND CAPACITIES, Information,Recommended lubricants andfluids . 14. Enter newspider withseals intoyokes ofsliding member flange. 15. Partially insertonebearing cupintoflange yoke and enter spider trunnion intobearing cup. 16. Insert opposite bearingcupintoflange yoke. 17. Press bothcups intoplace. 18. Press eachcupintoitsrespective yokeupto lower landofcirclip grooves. Damagemaybe caused tocups andseals ifcups passthispoint. 19. Fitcirclips andcheck noend float exists. 20.Engage spiderinyokes ofsliding member. Fit bearing cupsandcirclips asdescribed in instructions 14to19. 21. Fitgrease nipples tospider andsliding member. 22. Apply instructions 14to19 toopposite endof propeller shaft. 23. Fitgrease nippleandlubricate. Refit 24. Fitpropeller shaftstovehicle withsliding jointsto transfer boxand tighten nutsto 47Nm (35 lbf/ft).
REARAXLEANDFINAL DRIVE 1 DESCRIPTION ANDOPERATION DESCRIPTION The welded steelrearaxle casing houses aseparate spiral bevel typedifferential unit,which isoff set tothe right ofthe vehicle centreline.Thedifferential unit drives therear wheels viathe axle shafts andfully floating hubswhich aremounted ontapered roller bearings.LubricationThe differential islubricated withoiland thehub bearings withgrease. The hubbearings arefitted withinner andouter seals. The outer seals prevent thedifferential oilmixing with the hub grease andtheinner seals prevent dirt ingress intothehub. VentilationVentilation ofthe hub bearings isthrough theouter oil seals andthedifferential ventilationpipe,which terminates atahigh level. Rear axlehub-90 1. Axle casing 2. Ventilation pipe 3. Axle shaft 4. Wheel studsandhub 5. Wheel bearing stubaxle 6. Wheel bearings 7. Inner hubseal 8. Outer hub/axle shaftseal 9. Hub lockplate, thrust washer andnuts 10. Brake disc
51REAR AXLEANDFINAL DRIVE 2 DESCRIPTION ANDOPERATION Rear axlehub-110/130 1. Axle casing 2. Ventilation pipe 3. Axle shaft 4. Wheel studsandhub 5. Wheel bearing stubaxle 6. Wheel bearings 7. Inner hubseal 8. Outer hub/axle shaftseal 9. Hub lockplate, thrust washer andnuts 10. Brake disc 11. Drive flange 12. Drive shaftcirclip 13. Dust cap
REARAXLEANDFINAL DRIVE 1 FAULT DIAGNOSIS FAULT DIAGNOSIS Complaint -Oil leaks An external leakoflubrication fromthehub seals can be caused byafaulty internal seal.Forexample, ifthe seals which separate thedifferential fromthehubs are faulty andthevehicle isoperating orparked onan embankment, oilfrom thedifferential mayflood one hub resulting inalack oflubrication inthe differential. When aseal isfound tobe leaking checktheaxle ventilation system,asablockage cancause internal pressure toforce oilpast theseals. See Description andOperation forillustrations ofoil seal locations. When investigating hubseal leaks check thegrease for dilution withoil.Also check thedifferential oillevel, for signs ofmetal particles inthe oiland thecondition of internal seals. If the vehicle isdriven indeep water withdefective oil seals, watermaycontaminate thelubricants andraise the differential oillevel, giving afalse impression that the housing hasbeen overfilled. Do not assume thatahigh oillevel inthe differential isdue toover filling or,that alow level is because ofan external leak.
REARAXLEANDFINAL DRIVE 1 REPAIR REAR AXLE Service repairno-51.25.01 Remove WARNING: Removeandrefit ofaxle requires afurther twopersons tosteady the axle when lowering orrepositioning axle. 1. Drain brake system. 2. Support chassisrear. 3. Remove roadwheels. 4. Support axleweight withhydraulic jack. 5. Disconnect shockabsorbers. 6. Disconnect flexiblebrakehoseatRH chassis side member andbreather hoseatbanjo connection onaxle casing. 7. Disconnect lowerlinksataxle. 8. Mark differential andpropeller shaftflanges with identification marksforassembly. 9. Remove 4nuts andbolts, lowerpropeller shaft and tietoone side. 10. Disconnect pivotbracket balljoint ataxle bracket. 11. Release boltsandremove coilspring retaining plates. 12. Lower axleandremove roadsprings. 13. Ifapplicable, removeanti-rollbarlinks ataxle See REAR SUSPENSION, Repair,anti-roll bar . 14. Remove axleassembly.
51REAR AXLEANDFINAL DRIVE 2 REPAIR REV:09/97 Refit 15. Position axleandfitlower links.Tighten fixings to 176 Nm(130 lbf/ft). 16.Ifapplicable, fitanti-roll barlinks toaxleSee REAR SUSPENSION, Repair,Anti-roll bar links . 17. Raise axleandlocate roadsprings. 18. Fitcoil spring retaining platesandsecure with fixing bolts. 19. Secure pivotbracket balljoint toaxle bracket. Tighten fixingto 176Nm(130 lbf/ft). 20.Align propeller shafttodifferential driveflange and tighten fixingsto 47Nm (35lbf/ft). 21. Reconnect flexiblebrakehoseandaxle breather hose. 22. Refit shock absorbers. 23. Fitroad wheels andtighten tocorrect torque: Alloy wheels - 130Nm(96lbf/ft) Steel wheels -100Nm(80lbf/ft) Heavy Dutywheels -170Nm(125 lbf/ft) 24.Remove rearchassis support. 25. Bleed brakesystem SeeBRAKES, Repair, brake system bleed .