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Land Rover Defender Workshop Rover Manual

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    							REARAXLEANDFINAL DRIVE
    1
    SPECIFICATIONS,
    TORQUE
    TORQUE
    VALUES
    NOTE:Torque wrenches shouldberegularly checkedforaccuracy toensure thatallfixings are
    tightened tothe correct torque.
    Nm
    REAR AXLE
    Pinion housing toaxle case 41
    .......................................................................
    Crown wheeltodifferential case 58
    ................................................................
    Differential bearingcaptopinion housing 90
    ..................................................
    Differential driveflange todrive shaft 47
    .........................................................
    Bevel pinion nut 129
    ........................................................................................
    Lower linktoaxle 176
    ......................................................................................
    Pivot bracket balljoint toaxle 176
    ...................................................................  
    						
    							FRONTAXLEANDFINAL DRIVE
    1
    DESCRIPTION
    ANDOPERATION
    DESCRIPTION The
    welded steelfrontaxlecasing houses aseparate
    spiral bevel typedifferential unit,which isoff-set tothe
    right ofthe vehicle centreline.Thedifferential unit
    drives thefront wheels viathe axle shafts and
    constant velocityjointswhich aretotally enclosed in
    the spherical andswivel housings. The
    front wheels arepivoted ontape roller bearings at
    the topand bottom ofthe swivel housing. Thewheel
    hubs onallaxles aresupported bytwo taper bearings
    and driven bydrive flanges whicharesplined tothe
    one piece, stubshaft/constant velocityjoint.
    Frontaxlehubandswivel housing
    1. Axle casing
    2. Ventilation pipe
    3. Axle shaft
    4. Wheel studsandhub
    5. Stub axle
    6. Wheel bearings
    7. Inner andouter hubseals
    8. Axle shaft seal
    9. Hub lockplate, thrust washer andnuts
    10. Brake disc
    11. Drive flange
    12. Shim washer andcirclip 13.
    Dust cap
    14. Constant velocityjoint/shaft
    15. Thrust collarforCV joint
    16. Roller bearing
    17. Spacer
    18. Circlip
    19. Top andbottom swiveltaperbearing
    20. Top andbottom swivelpins
    21. Spherical housing,sealandretainer
    22. Swivel housing
    23. Constant velocityshaftseal   
    						
    							54FRONT
    AXLEANDFINAL DRIVE
    2 DESCRIPTION
    ANDOPERATION
    Lubrication The
    differential, swivelpinhousing andwheel hubs
    are indiviudally lubricatedandseparated byoilseals
    (7) and (8),see J6267A, toprevent oiltransfer across
    the axle when thevehicle istraversing steepinclines.
    The wheel bearings arelubricated withgrease andthe
    swivel housing anddifferential withoil.On later
    vehicles, identified byhaving onlyafiller plug inthe
    swivel housing, greaseisused tolubricate the
    housing assembly,
    VentilationVentilation ofthe differential isthrough aplastic pipe
    (2) which terminates atahigh level inthe vehicle axle.
    The swivel housings ventilatethroughaxleshaft oil
    seals (8)into thedifferential andthehub bearings
    vent viathe oilseals intotheswivel housing. 
    						
    							FRONTAXLEANDFINAL DRIVE
    1
    FAULT
    DIAGNOSIS
    FAULT
    DIAGNOSIS
    Complaint -Oil leaks
    An external leakoflubrication canbecaused bya
    faulty internal seal.Forexample, ifthe seals which
    separate thedifferential fromtheswivel housings are
    faulty andthevehicle isoperating orparked onan
    embankment, oilmay leakacross theaxle leaving one
    swivel withahigh level andtheopposite swiveland
    differential lackinglubrication.
    See Description andOperation forillustrations ofoil
    seal locations.
    When investigating leaksorchecking oillevels, itis
    essential thatallthe lubrication isdrained fromany
    housing withahigh level andthattheother levels are
    checked. Swivel oilshould bechecked forsigns ofgrease
    leaking fromthehub bearings andoilcontamination of
    the hub grease.
    Check thattheaxle ventilation systemisclear, asa
    blockage cancause internal pressure toforce oilpast
    the seals.
    If the vehicle isdriven indeep water withdefective oil
    seals, watermaycontaminate thelubricants andwhen
    checked, giveafalse impression thatthehousing has
    been overfilled withoil.
    Do not assume thatahigh oillevel isdue toover
    filling or,that alow level isbecause ofan external
    leak .  
    						
    							FRONTAXLEANDFINAL DRIVE
    1
    REPAIR
    REV: 09/97
    FRONT
    AXLEASSEMBLY
    Service repairno-54.10.01
    Remove
    WARNING: Removeandrefit ofaxle
    requires afurther twopersons tosteady
    axle when lowering orrepositioning axle.
    1. Support chassisfront.
    2. Remove roadwheels.
    3. Support axleweight withhydraulic jack.
    4.Remove radiusarmstochassis framenuts.
    5. Disconnect steeringdamperfromtrack rod.
    Using aextractor removetrackrodlinks from
    swivel pinarms.
    6. Remove fournuts andbolts securing radius
    arms toaxle bracket.
    7. Remove radiusarms.
    8. Remove boltssecuring brakehosebrackets .
    Refit bolts toprevent oilleakage.
    9. Remove boltsfrombrake calipers andtietoone
    side.
    10. Remove nutsandwashers securing shock
    absorbers toaxle.
    11. Disconnect draglinkfrom swivel pinhousing
    arm.
    12. Remove twonuts andbolts securing panhard
    rod toaxle bracket. Liftrod clear ofaxle.
    13. Mark forreassembly driveshaftflanges.
    Remove fournuts andbolts, tiepropeller shaftto
    one side.
    14. Release axleventilation pipebanjo andlower
    axle assembly. Removeroadsprings.
    15. Disconnect anti-rollbarlink
    See FRONT
    SUSPENSION, Repair,Anti-roll barball
    .
    16. Remove axleassembly.
    Refit 17. Position axleunder vehicle, supporting leftside
    of axle, andfitanti-roll barlinks
    See FRONT
    SUSPENSION, Repair,Anti-roll barlinks
    .
    18. Fitpropeller shaft.Tighten boltsto
    47Nm (35
    lbf/ft).
    19. Fitpanhard rodtoaxle bracket. Tightenboltsto
    88Nm (65lbf/ft).
    20. Fitdrag linktoswivel pinarm. Tighten fixingsto
    40Nm (30lbf/ft).
    21. Fitshock absorbers toaxle.
    22. Fitbrake calipers. Tightenboltsto
    82Nm (60
    lbf/ft).
    23. Tighten upperswivel pinbolts to78Nm (58
    lbf/ft).
    24. Fitradius armstoaxle brackets. Tightenboltsto
    197Nm(145 lbf/ft).
    25.Fitsteering dampertotrack rod.
    26. Fitradius armstochassis sidemember. Tighten
    fixings to
    197Nm(145 lbf/ft).
    27.Tighten trackrodend to40Nm (30lbf/ft)and fit
    new splitpin.
    28. Remove chassissupports, fitroad wheels and
    tighten tocorrect torque:
    Alloy wheels -
    130Nm(96lbf/ft)
    Steel wheels -100Nm(80lbf/ft)
    Heavy dutywheels -170Nm(125 lbf/ft)    
    						
    							54FRONT
    AXLEANDFINAL DRIVE
    2 REPAIR
    FRONT
    HUBASSEMBLY
    Service repairno-60.25.01.
    Remove 1. Loosen frontwheel nuts,jackupvehicle and
    lower ontoaxlestands andremove roadwheel.
    2. Release brakehoseclipsandremove brake
    caliper andbrake discshield bolts.Secure to
    one side. 3.
    Lever offdust cap.
    4. Remove circlipanddrive shaftshimfrom
    driveshaft.
    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 shaftshim.
    4. Drive member.
    5. Drive member jointwasher.
    6. Drive member retaining bolt.
    7. Lock nut.
    8. Lock washer. 9.
    Hub adjusting nut.
    10. Spacing washer.
    11. Outer bearing.
    12. Hub.
    13. Inner bearing.
    14. Grease seal.
    15. Brake disc
    16. Disc retaining bolt.  
    						
    							FRONTAXLEANDFINAL DRIVE
    3
    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. Fitoriginal driveshaftshimandsecure witha
    circlip.
    20. Tocheck driveshaftendplay, mount adial
    gauge usingbracket LRT-99-503 andrestpinin
    a loaded condition onend ofdrive shaft.
    21. Fitasuitable bolttothreaded endofdrive shaft.
    Move driveshaftinand outnoting dialgauge
    reading. Endplay should bebetween 0,08to
    0,25 mm.
    22. Ifend play requires adjustment, removecirclip,
    measure shimthickness andfitan appropriate
    shim togive required end-play.
    23. Remove boltfrom drive shaft, fitcirclip anddust
    cap.
    24. Fitbrake discshield andbrake caliper. Tighten
    fixings to
    82Nm (60lbf/ft).
    25. Bleed brakesystemSeeBRAKES, Repair,
    Brake system bleed
    .
    26. 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)
    27.Operate footbrake tolocate brakepadsbefore
    driving vehicle.    
    						
    							FRONTAXLEANDFINAL DRIVE
    1
    OVERHAUL
    FRONT
    DIFFERENTIAL
    Service repairno-54.10.07.
    Overhaul
    NOTE: Thefront axledifferential, forall
    models, isthe same asthat fitted tothe 90
    rear axle andcanonly beserviced asa
    complete assembly
    SeeREAR AXLEANDFINAL
    DRIVE, Repair, Differential assembly-90
    .
    FRONT HUB
    Service repairno-60.25.14.
    Overhaul 1. Remove hubassembly
    See Repair, Fronthub
    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.
    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 toolLST 137seal replacer anddrift18G
    134 .Drive inseal flush withrearface ofhub.
    Apply grease between seallips.
    10. Fitbrake disctohub, lining uptomarks made
    during dismantling. ApplyingLoctite270,fit
    retaining bolts.Tighten to
    73Nm (54lbf/ft).
    11. Grease andfitouter bearing tohub.
    12. Fithub assembly
    See Repair, Fronthub
    assembly
    .    
    						
    							54FRONT
    AXLEANDFINAL DRIVE
    2 OVERHAUL
    FRONT
    STUBAXLE, CONSTANT VELOCITYJOINT
    AND SWIVEL PINHOUSING
    Service repairno-60.15.43.
    Remove stubaxle, axleshaft andconstant
    velocity joint.
    1. Remove fronthubassembly
    See Repair, Front
    hub assembly
    .
    2. Drain swivel pinhousing andrefitplug.
    NOTE: Onlater vehicles theswivel pin
    housing isfilled withgrease forlife, the
    level anddrain plugs beingdeleted.
    3.Remove 6bolts retaining stubaxletoswivel
    housing.
    4. Remove mudshield.
    5. Remove stubaxleandjoint washer.
    6.Wthdraw axleshaft andconstant velocityjoint
    from axlecasing.
    Remove constant velocityjointfrom axleshaft
    7. Hold axleshaft firmly inasoft jawed vice.
    8. Using asoft mallet driveconstant velocityjoint
    from shaft.
    9. Remove circlipandcollar fromaxleshaft.
    Constant velocityjoint
    10. Mark positions ofconstant velocityjoint,inner
    and outer raceandcage forreassembly.
    11. Swivel cageandinner racetoremove balls.     
    						
    							FRONTAXLEANDFINAL DRIVE
    3
    OVERHAUL
    12.
    Examine allcomponents, inparticular, innerand
    outer track, cageballsandbearing surfaces for
    damage andexcessive wear.
    13. Maximum acceptable end-floatonassembled
    joint 0,64mm. Renewifworn ordamaged.
    Lubricate witharecommended oilduring
    assembly.
    Fit constant velocityjointtoaxle
    14. Fitcollar andanew circlip.
    15. Engage constant velocityjointonaxle shaft
    splines andusing asoft mallet, drivejointinfully.
    Renew stubaxle, thrust ring,oilseal andbearing
    16. Drillandchisel offthrust ringtaking caretoavoid
    damaging stubaxle.
    17.Remove bearingandoilseal using special tool
    TRT-37-004 andslide hammer LRT-99-004 .
    Ensure lipoftool locates behindbearing toto
    drive itout.
    18. Repeat instruction forremoval ofoil seal.
    19. Lubricate sealandlipwith EP90 oiland with
    cavity sideleading pressinanew oilseal using
    special toolLRT-54-004 .
    20.Using special toolLRT-54-005 ,fit bearing with
    its part number visiblewhenfitted, andflush with
    end face ofstub axle.
    21. Press fitanew thrust ringonto stubaxle.      
    						
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