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.