Land Rover Defender Workshop Rover Manual

							REARAXLEANDFINAL DRIVE
3
REPAIR
REAR
HUBASSEMBLY -90
Service repairno-64.15.01
Remove 1. Place rearaxle onto axlestands andremove
road wheel.
2. Release brakehoseclipsandremove brake
caliper bolts.Secure toone side.
WARNING: Takecarenottokink brake
hose.
3. Remove 5bolts andwithdraw axleshaft.
4. Remove jointwasher.
5. Bend backlockwasher tabs.
6. Remove locknutandlock washer.
7. Remove hubadjusting nut.
8. Remove spacingwasher.
9. Remove hubandbrake discassembly complete
with bearings.
Rear hubcomponents -90
1. Axle shaft.
2. Axle shaft jointwasher.
3. Axle shaft retaining bolt.
4. Lock nut.
5. Lock washer.
6. Hub adjusting nut.
7. Spacing washer. 8.
Outer bearing.
9. Hub.
10. Inner bearing.
11. Grease seal.
12. Brake disc.
13. Disc retaining bolt.   
						

							51REAR
AXLEANDFINAL DRIVE
4 REPAIR
REV:09/97
Refit
10. Clean stubaxle.
11. Fithub assembly tostub axle.
12.Fitspacing washer.
13. Fithub adjusting nut.Tighten to
50Nm (37
lbf/ft).
Ensure hubisfree torotate withno
bearing play.Back offadjusting nut90°and
tighten to
10Nm (7lbf/ft).
14. Fitanew lockwasher.
15. Fitlocknut. Tightento
50Nm (37lbf/ft).
16. Tab over lockwasher tosecure adjusting nut
and locknut.
17. Using anew jointwasher fitaxle shaft tohub.
Tighten boltsto
65Nm (48lbf/ft).
18. Fitbrake caliper. Tighten boltsto82Nm (61
lbf/ft).
Secure brakepipestoaxle casing.
19. Fitroad wheel, remove axlestands andtighten
road wheel nutstocorrect torque:
Alloy wheels -
130Nm(96lbf/ft)
Steel wheels -100Nm(80lbf/ft)
Heavy dutywheels -170Nm(125 lbf/ft)
20.Operate footbrake tolocate brakepadsbefore
driving vehicle.  
						

							REARAXLEANDFINAL DRIVE
5
REPAIR
REAR
HUBASSEMBLY -110/130
Service repairno-64.15.01
Remove 1. Loosen rearwheel nuts,jackupvehicle and
lower ontoaxlestands. Remove roadwheel.
2. Release brakepipeclips, remove brakecaliper
and brake discshield bolts.Secure toone side.
WARNING: Takecarenottokink brake
hose. 3.
Lever offdust cap.
4. Remove circlipfromdriveshaft.
5. Remove 5bolts andwithdraw drivingmember
and joint washer.
6. Bend backlockwasher tabs.
7. Remove locknutandlock washer.
8. Remove hubadjusting nut.
9. Remove spacingwasher.
10. Remove hubandbrake discassembly complete
with bearings.
Hub components
1. Dust cap.
2. Drive shaftcirclip.
3. Drive member.
4. Drive member jointwasher.
5. Drive member retaining bolt.
6. Lock nut.
7. Lock washer.
8. Hub adjusting nut. 9.
Spacing washer.
10. Outer bearing.
11. Hub.
12. Inner bearing.
13. Grease seal.
14. Brake disc
15. Disc retaining bolt.   
						

							51REAR
AXLEANDFINAL DRIVE
6 REPAIR
REV:09/97
Refit
11. Clean stubaxleanddrive shaftandfithub
assembly toaxle.
12. Fitspacing washer.
13. Fithub adjusting nut.Tighten to
50Nm (37
lbf/ft) .
Ensure hubisfree torotate withno
bearing play.
14. Back offadjusting nut90°and tighten to
10Nm
(7 lbf/ft).
15. Fitanew lockwasher.
16. Fitlocknut. Tightento
50Nm (37lbf/ft).
17. Tab over lockwasher tosecure adjusting nut
and locknut.
18. Fitanew jointwasher todriving member andfit
member tohub. Tighten boltsto
65Nm (48
lbf/ft).
19. Fitcirclip anddust cap.
20. Fitbrake discshield andbrake caliper. Tighten
bolts to
82Nm (61lbf/ft).
21. Bleed brakesystemSeeBRAKES, Repair,
Brake system bleed
.
22. Fitroad wheel, remove axlestands andtighten
road wheel nutstocorrect torque:
Alloy wheels -
130Nm(96lbf/ft)
Steel wheels -100Nm(80lbf/ft)
Heavy dutywheels -170Nm(125 lbf/ft)
23.Operate footbrake tolocate brakepadsbefore
driving vehicle.  
						

							REARAXLEANDFINAL DRIVE
7
REPAIR
DIFFERENTIAL
ASSEMBLY-90
Service repairno-51.15.01
Remove 1. Using suitable container, drainaxleoil.
2. Mark differential andpropeller shaftflanges to
facilitate reassembly.
3.Remove 4bolts anddisconnect propellershaft
from differential. Tieaside.
4. Remove 5hub drive member boltsandwithdraw
axle halfshafts sufficiently todisengage from
differential unit.
5. Remove 10nuts securing differential toaxle
case.
6. Withdraw differential unit.
NOTE:Thedifferential unitcanonly be
serviced asacomplete assembly with
matching drivepinion. Foradvice ring
Land Rover Service Department. Refit
7. Ensure matingfacesareclean andapply abead
of RTV sealant toaxle case.
8. Support differential unitand position onaxle
casing.
9. Secure withselflocking nutsandtighten to
40
Nm (30lbf/ft).
10. Align marks onflanges andsecure propeller
shaft todifferential. Tightenboltsto
48Nm (35
lbf/ft).
11. Refit halfshafts, usingnewdrive member
gaskets. Tightenboltsto
65Nm (48lbf/ft).
12. Refill axleoilwith approved lubricantSee
LUBRICANTS, FLUIDSANDCAPACITIES,
Information, Recommended lubricantsand
fluids
.   
						

							REARAXLEANDFINAL DRIVE
1
OVERHAUL
DIFFERENTIAL
ASSEMBLY-110/130
Service repairno-51.15.07
Overhaul 1. Drain offdifferential lubricatingoil,and refitplug.
2. Remove rearaxle assembly fromvehicle
See
Repair, Rearaxle
3.Remove hubdriving member fixings.
4. Withdraw drivingmember andaxle shaft
sufficiently todisengage differential.
5. Repeat instruction 4for other axleshaft.
6.Remove fixingsandsupport stripatdifferential
cover andwithdraw coverandjoint washer.
7. Note relationship markingonbearing capsand
axle casing toensure correctrefitting.
8. Remove fixingsandwithdraw differential bearing
caps.
9. Clean outand examine spreader toolpegholes
provided ingear casing face;ensure thatholes
are free from dirtand burrs anddamage.
10. Ensure thatturnbuckle adjusterisfree toturn.
Using axlespreader 18G31C
11. Fitaxle spreader toengage pegholes.
(Spreader 18G131C,Adaptor pegs18G131F )
12. Using aspanner, turnadjuster untilallfree play
between spreader andcasing istaken up,
denoted byadjuster becoming stifftoturn.
13. Check thatside members ofspreader areclear
of casing.
14. Stretch casing, rotating adjuster byone flatata
time, untildifferential assemblycanbelevered
out. Donot lever against spreader; usesuitable
packing underlevers toavoid damage tocasing.     
						

							51REAR
AXLEANDFINAL DRIVE
2 OVERHAUL
CAUTION:
Toprevent permanent damage
to the gear carrier case,itmust notbe
over-stretched. Eachflatonthe turnbuckle
is numbered toenable acheck tobe made onthe
amount turned.Themaximum stretchpermitted is
0,30 mm, equivalent tothree flats.
15. Ease offadjuster andremove spreader.
Usingaxlecompressor LRT-51-503(GKN131)
16. Place toolontodifferential casing,asillustrated,
with weld seam uppermost. Ensurethatplates
rest squarely ondifferential machinedsurface
and endbars buttagainst edgesofcasing.
17. Tighten adjusting nutsbyhand only,untilall
slack istaken up.
18. Continue totighten bothnutsalternately witha
spanner, oneflatatatime, toamaximum of
three flats.
19. Carefully lever-outdifferential assembly.
Dismantle differential
20. Add alignment marksbetween crownwheeland
differential caseforreassembly purposes,then
remove fixingsandwithdraw crownwheel.
21.Note alignment markingsontwo differential
casings toensure correctrefitting, thenremove
fixings.
22. Liftoffupper case.
23. Withdraw upperdifferential wheelandthrust
washer.
24. Liftout cross-shaft andpinions.    
						

							REARAXLEANDFINAL DRIVE
3
OVERHAUL
25.
Withdraw fourdished thrustwashers.
26. Withdraw lowerdifferential wheelandthrust
washer.
27. Remove differential bearingconesusing
LRT-51-500 ,adaptors 1and 2and press
LRT-99-002 .
28. Withdraw shimwashers fittedbetween bearing
cones anddifferential casings.
Removefinaldrive pinion
29. Using LTR-51-003 toprevent coupling flange
from rotating, removeflangelocknut andplain
washer.
30. Support drivepinion andremove coupling flange
by tapping withahide hammer.
31. Withdraw drivepinion togerwithinner bearing
cone.
32. Withdraw anddiscard collapsable bearing
spacer.
33. Withdraw oilseal, gasket andoilthrower.
34. Withdraw outerbearing cone.
35. Using LRT-51-502 ,extract pinioninnerbearing
cup and shim washers fromcasing. Noteshim
washer thickness. .
36. Extract pinionouterbearing cupfrom casing
using LRT-51-502 .      
						

							51REAR
AXLEANDFINAL DRIVE
4 OVERHAUL
37.
Using LRT-51-500 andpress LRT-99-002 ,
remove innerbearing conefrompinion.
INSPECTION 38. Examine allcomponents forobvious wearor
damage.
39. Bearing conesmustbeapress fiton their
locations, exceptdrivepinion flange andbearing
which isaslide fit.
40. The crown wheelandpinion aresupplied asa
matched pairand must notbeinterchanged
separately. Anew crown wheelandpinion
matched pairmay befitted toan original gear
carrier casing ifsound. original crownwheeland
pinion, ifsound, maybefitted intoareplacement
casing.
41. The twoparts ofdifferential unitcasing are
matched andmust notbereplaced separately.
42. Discard andrenew allthrust washers.
43. Differential housingswithworn thrust washer
seatings mustbereplaced asapair.
44. Examine differential casetocrown wheeljoint
face forburrs anddamage whichcouldleadto
crown wheelrun-out whenfitted. ASSEMBLE Differential
45. Fitdifferential lowerwheel andthrust washer to
differential case.Seeillustration following
instruction 23.
46. Fitdished thrustwashers.
47. Fitcross-shaft andpinions.
48. Fitdifferential upperwheel andthrust washer.
49. Fitdifferential uppercaselining-up marks.
50. Secure assembly withbolts using Loctite
Studlock gradeCVXonthreads andtighten
evenly anddiametrically to
95Nm (70lbf/ft).
51. Fitcrown wheeltodifferential casing.UseLoctite
Studlock gradeCVXonfixing boltthreads and
tighten tocorrect torque.
52. Press ondifferential rollerbearing conesless
shim washers, usingLRT-51-504 ,and leave to
one side untilrequired forinstruction 96.
53. Fitbearing cupstodifferential.
54. Fitdifferential unitand bearings togear carrier
casing, androtate unittocentralize bearings.Do
not fitbearing caps.   
						

							REARAXLEANDFINAL DRIVE
5
OVERHAUL
55.
Position asuitable dialgauge indicator oncasing
with stylus registering onback faceofcrown
wheel.
56. Rotate differential andcheck totalindicated
run-out oncrown wheelbackface. Thismust not
exceed 0,05mm.Ifrun-out isexcessive, check
mating facesfordirt and damage; ifnecessary,
select anew radial position forcrown wheel.
When satisfactory, continuewithfollowing check.
Differential bearingadjustment
57. Insert twolevers between casinganddifferential
unit atone side.
58. Move differential unitfully toone side ofcasing;
do not tiltunit.
59. Rotate differential unittosettle bearings,
continue tolever differential toside, thenzero
dial gauge indicator.
60. Lever assembly fullytoother sideofcasing,
rotate unittosettle bearings, thennotetotal
indicator reading.
61. Add 0,127 mm,forbearing pre-load, tototal
noted inpreceding instruction. Thesum isthen
equal tonominal valueofshims required for
differential bearings.Shimsareavailable in
range 0,07mm,0,12 mm,0,25 mmand 0,76
mm. Select totalvalue ofshims required.
62. Remove differential unitand bearings andplace
aside. Donot fitshim washers untilsubsequent
Differential backlashcheckshavebeen made,
instructions 96to102. Fit
drive pinion
63. Select shimwashers ofsame thickness valueas
those removed fromunder pinion innercup,
instruction 35,and place ready forfitting.
64. Position outerbearing replacer LRT-51-505 ,
detail 2,and outer bearing cuponpress
LRT-99-502 .
65. Locate assembly intopinion housing nose.
66. Place selected shimwashers ontoinner bearing
cup seating.
67. Position innerbearing cupincasing.
68. Position innerbearing replacer LRT-51-505 ,
detail 1,onto LRT-99-502 andsecure withfixing
nut.
69. Hold stillcentre screwandturn butterfly leverto
draw inbearing cups.