Land Rover Defender Workshop Rover Manual

							51REAR
AXLEANDFINAL DRIVE
6 OVERHAUL
70.
Press innerbearing coneontodrive pinion using,
LRT-51-502 details1and 2and press
LRT-99-002 .
71. Position pinionandbearing incasing; omit
collapsable spaceratthis stage.
72. Fitouter bearing coneontopinion.
73. Fitcoupling flangeandplain washer andloosely
fit flange nut.
74. Tighten coupling flangelocknut toremove
end-float frompinion.
75. Rotate piniontosettle bearings andslowly
tighten flangelocknut. Useaspring balance to
obtain atorque resistance of11 Kgf/cm (18
lbf/in) torotate pinion.
Drive pinion markings
76. Check thatserial number markedonpinion end
face matches thatmarked oncrown wheel.
77. The markings onend face adjacent toserial
number areofno significance duringservicing.
78. The figure marked onend face opposite toserial
number indicates, inthousandths ofan inch,
deviation fromnominal required tocorrectly set
pinion. Apinion marked plus(+)must beset
below nominal, aminus (-)pinion mustbeset
above nominal. Anunmarked pinionmustbeset
at nominal.
79. The nominal settingdimension isrepresented by
setting gaugeblock18G191P orLRT-54-503 ,
which isreferenced frompinion endface to
bottom radiusofdifferential bearingbore.The
latter gauge isillustrated followinginstruction 85.
Drivepinion adjustment
80. Ensure thatpinion endface isfree ofraised
burrs around etchedmarkings.
81. Remove keepdiscfrom magnetized baseofdial
gauge tool18G191 .
82. Place dialgauge andsetting gauge18G191P or
LRT-54-503 onaflat surface andzero dial
gauge stylusontosetting gauge.    
						

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OVERHAUL
83.
Position dialgauge centrally onpinion endface
with stylus registering onlowest pointonone
differential bearingbore.Notedialgauge
deviation fromzeroed setting.
84. Repeat onother bearing bore.Addtogether
readings, thenhalve sumtoobtain mean
reading. Notewhether stylushasmoved upor
down fromzeroed setting.
Example 1
Reading obtained LHside.............. +0.1524mm
Reading obtained RHside............. -0.0762mm
Add +0.1524mm -0.0762mm =+0.0762mm
Divide by2(0.0762 dividedby2)= 0.0381mm
Therefore subtract0.0381mm fromshim thickness
behind pinioninnerbearing track.
Example 2
Reading obtained LHside............. +0.1524mm
Reading obtained RHside............ -0.2032mm
Add +0.1524mm -0.2032mm =+0.0508mm
Divide by2(0.0508 dividedby2)= 0.0254mm
Therefore add0.0254mm fromshim thickness behind
pinion innerbearing track.
85.Where stylushasmoved down(85a), amount is
equivalent tothickness ofshims thatmust be
removed fromunder pinion innercuptobring
pinion downtonominal position. Wherestylus
has moved up(85b), amount isequivalent to
additional thicknessofshims required tobring
pinion uptonominal position.
Illustration A.Using setting gauge18G191P .
Illustration B.Using universal settingblock
LRT-54-503 .This setting blockhas3setting heights.
Ensure thatheight marked 30.93mmisused forthis
differential.     
						

							51REAR
AXLEANDFINAL DRIVE
8 OVERHAUL
86.
Before adjusting shimthickness, checkpinion
face marking andifithas aplus (+)figure,
subtract thatfrom shim thickness figureobtained
in previous instruction. Alternatively ifpinion has
a minus (-)figure, addamount toshim thickness
figure.
87. Adjust shimthickness underpinion innercupas
necessary, byamount determined ininstructions
85 and 86.
88. Recheck pinionheight setting instructions 82to
84. Ifsetting iscorrect, meanreading ondial
gauge willagree withfigure marked onpinion
end face. Forexample, withanend face marking
of +3, dial gauge reading shouldindicate that
pinion is0.003 in(0.0762 mm)below nominal.
89. When pinion setting issatisfactory, temporarily
remove pinionouterbearing.
90. Fitanew collapsable bearingspacer,flaredend
outward, todrive pinion andrefitouter bearing.
91. Fitpinion oilslinger.
92. Fitoilseal gasket.
93. Fitpinion oilseal, lipped sidefirst, using general
purpose greaseor,where available, a
molybdenum disulphidebasedgrease onseal
lip, using LRT-51-002 todrift inseal.
94. Fitcoupling flangeandplain washer andloosely
fit anew flange nut.Secure LRT-51-003 to
coupling flange,usingslavefixings.
95.Alternately tightenflangenutand check drive
pinion resistance torotation untilfollowing
figures areachieved, asapplicable:
A. Assemblies re-usingoriginalpinionbearings:
17,3 to34,5 kgfcm.
B. Assemblies withnew pinion bearings: 34,5to
46,0 kgfcm.
NOTE: Oncethebearing spacerhas
started tocollapse thetorque resistance
build-up israpid, therefore check
frequently, usingaspring balance, toensure the
correct figuresarenot exceeded, otherwiseanew
collapsable bearingspacerwillberequired.    
						

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OVERHAUL
Differential
backlashchecks
96. Pick updifferential unitasleft after instruction
52.
97. Fitdifferential unitand lever unitaway fromdrive
pinion untilopposite bearingcupisseated
against housing. Donot tiltunit.
98. Install adial gauge oncasing withitsstylus
resting onback faceofcrown wheel. Zerothe
gauge.
99. Lever differential unittoengage crownwheel
teeth infull mesh withdrive pinion teeth.Donot
tilt unit.
100. Notetotalreading obtained ondial gauge.
101. From thisfigure subtract 0,25mmtoobtain
correct crownwheelbacklash whenfitted. The
result indicates valueofshimming tobe fitted
between differential caseandbearing coneat
crown wheelsideofdifferential.
102. Fitshim value determined ininstruction 101,
taking shimsfrompack previously determined
during Differential bearingadjustment checks,
instructions 57to62 LRT-51-500 details1and 2,
press LRT-99-002 ,and LRT-51-504 .
103. Fitremaining shimsfrominstruction 101to
opposite sideofdifferential. LRT-51-501 details
1 and 2,press LRT-99-002 ,and LRT-51-504 .
104. Fitdifferential unitwith shims andbearings to
axle casing, usingaxlespreader LRT-51-503
with pegs 18G131F .
105. Remove axlespreader. 106.
Fitbearing capsintheir correct position,
referring torelationship markingsoncaps andon
axle casing.
107. Tighten bearingcapsfixings to
135Nm(100
lbf/ft).
108. Mount adial gauge onaxle casing withstylus
resting onacrown wheeltooth.
109. Prevent drivepinion fromrotating andcheck
crown wheelbacklash whichmustbe0,15 to
0,27 mm.Ifbacklash isnot within specified
limits, repeat differential backlashchecks,
instructions 96to102 looking forpossible errors.
110. Fitdifferential coverandnew gasket, coating
both sides ofgasket withHylomar PL32M oran
equivalent non-setting sealant.Torqueloadfor
fixings is
30Nm (22lbf/ft).
111. Reverse instructions 3to 5 and coat threads of
hub driving member boltswithLoctite Studlock
grade CVXandfitand tighten boltsevenly to
correct torque.
112. Fitrear axle assembly tovehicle
See Repair,
Rear axle
.
113. Replenish differential withrecommended
lubricant
See LUBRICANTS, FLUIDSAND
CAPACITIES, Information,Recommended
lubricants andfluids
.After initial axlerun,
check oillevel andreplenish asnecessary to
filler/level plughole.
114. Where majorrunning partshavebeen replaced
during servicing, itis arecommended practiceto
allow axleassembly torun inby avoiding,
where possible, heavyloadsandhigh speeds
during initialrunning.    
						

							51REAR
AXLEANDFINAL DRIVE
10 OVERHAUL
REAR
HUBASSEMBLY -90
Service repairno-64.15.13.
1. Remove rearhub
See Repair, Rearhub
assembly
.
2. Remove outerbearing.
3. Mark, forreassembly, positionofhub tobrake
disc. 4.
Remove 5bolts andseparate hubfrom brake
disc.
WARNING: Amaximum oftwo road wheel
retaining studscanberenewed. Should
more studs beunserviceable fitnew hub
with studs.
5. Remove greasesealandinner bearing from
hub.
6. Remove innerandouter bearing tracks.
REARHUBCOMPONENTS -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.  
						

							REARAXLEANDFINAL DRIVE
11
OVERHAUL
Refit
7. Clean hubandfitinner andouter bearing tracks.
8. Pack hubinner bearing withgrease andfitto
hub.
9. With lipside leading, fitanew sealflush with
rear face ofhub. Using service toolLRT-54-003
(LST137) sealreplacer anddrift. Apply grease
between seallips. 10.
Assemble brakedisctohub, lineupreassembly
marks. Applying Loctite270,fitand tighten
retaining boltsto
73Nm (54lbf/ft).
11. Pack hubouter bearing withgrease andfitto
hub.
12. Fitrear hubassembly
See Repair, Rearhub
assembly
.    
						

							51REAR
AXLEANDFINAL DRIVE
12 OVERHAUL
REAR
STUBAXLE-90
Service repairno-64.15.22.
STUB AXLECOMPONENTS
1. Stub axletoaxle casing bolt.
2. Mudshield.
3. Stub axle.
4. Stub axlejointwasher.
5. Axle case. Overhaul
1. Remove hubassembly
See Repair, Rearhub
assembly
.
2. Remove 6bolts fromstubaxletoaxle casing.
3. Remove mudshield.
4. Remove stubaxleandjoint washer.
Renew rearstub axleoilseal
5.Remove anddiscard oilseal. Lubricate sealand
lip with EP90 oil.Using special toolLRT-51-004
(LST 138)fitnew oilseal lipside trailing sothat
seal isflush withrearface ofstub axle.
Refit 6. Fitnew jointwasher, stubaxleandmudshield
bolts. Tighten boltsto
65Nm (48lbf/ft).
7.Refit hubassemblySee Repair, RearHub
Assembly
.   
						

							REARAXLEANDFINAL DRIVE
13
OVERHAUL
REAR
HUB-110/130
Service repairno-64.15.14.
Overhaul 1. Remove rearhubassembly
See Repair, Rear
hub assembly.
2.Remove outerbearing.
3. Mark, forreassembly, relationshipbetweenhub
and brake disc,iforiginal hubisto be refitted.
4. Remove 5bolts andseparate hubfrom brake
disc.
5. Drift outgrease sealandinner bearing fromhub
and discard seal.
HUBCOMPONENTS
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
14 OVERHAUL
6.
Drift outinner andouter bearing tracks.
7. Clean hubanddriftininner andouter bearing
tracks.
8. Pack hubinner bearing withrecommended
grease andfitto hub.
9. With lipside leading, fitnew sealtohub using
special toolLRT-54-003 (LST137)sealreplacer
and drift18G 134.Drive inseal flush withrear
face ofhub. Apply grease between seallips. 10.
Fitbrake disctohub, lining uptomarks made
during dismantling. apllyingLoctite270,fit
retaining bolts.Tighten to
73Nm (54lbf/ft).
11. Grease andfitouter bearing tohub.
12. Fithub assembly
See Repair, Rearhub
assembly
.   
						

							REARAXLEANDFINAL DRIVE
15
OVERHAUL
REAR
STUBAXLE-110/130
Service repairno-64.15.22
STUB AXLECOMPONENTS
1. Rear axleshaft
2. Stub axletoaxle casing bolt
3. Mudshield
4. Stub axle
5. Stub axlejointwasher
6. Axle case Overhaul
1. Remove hubassembly
See Repair, Rearhub
assembly
.
2. Remove 6bolts fromstubaxletoaxle casing.
3. Remove mudshield.
4. Remove stubaxleandjoint washer.
5. Remove rearaxle shaft fromaxlecasing.
Renew rearstub axleoilseal
6.Remove anddiscard oilseal. Lubricate sealand
lip EP90 oil.Using special toolLRT-51-004
(LST138) fitnew seallipside trailing sothat seal
is flush withrearface ofstub axle.
Refit 7. Fitnew jointwasher, stubaxleandmudshield.
Tighten boltsto
65Nm (48lbf/ft).
8.Fitrear axle shaft, avoiddamaging stubaxle
seal.
9. Refit hubassembly
See Repair, Rearhub
assembly
.