Land Rover Range Rover Classic Workshop 1995 Rover Manual

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OVERHAUL 23.Fit the snap ring with the stepped ends adjacent
to the selector shaft bore.
24.Turn the rear cover over and fit the circlip to
retain the sun gear shaft.
25.Remove any previous sealant from the end cap.
Apply Dow Corning 732 silicon sealant or a
suitable equivalent to the outside diameter of the
rear cover, evenly tap the cap into position.
26.If necessary re - position the filter on the oil pick
- up pipe until the lug on the filter can be pushed
into the slot in the rear...

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OVERHAUL Selector fork - Assemble
7.Fit new nylon slippers to the fork.
8.Assemble the fork to the selector arm and
secure in position using a new retaining clip.
9.Lightly lubricate and fit the spring and selector
plunger.
10.While compressing the plunger and spring, fit the
selector fork, operating arm assembly and
selector sleeve simultaneously.
11.Select neutral gear position at the operating arm.
12.Fit a new O ring to the selector lever shaft.
Lubricate the O ring and fit the...

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OVERHAUL Transfer shaft
- Inspection and assemble
1.Clean the transfer shaft.
2.Visually examine the external splines for
damage and wear, if worn fit a new component.
3.Check the phospher bronze bush for wear by
measuring the internal diameter of the bush with
internal calipers and a micrometer or with an
internal micrometer. The bush diameter must not
exceed 38.515 mm (1.516 in) fit a new transfer
shaft if the bush has worn above the figure
given.
4.Drive or press the transfer shaft into...

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OVERHAUL Centre differential and sprocket
- Dismantle and inspection
1.Place the differential unit in a vice fitted with soft
jaws. If the original components are to be refitted
mark an identification line on the sprocket and
differential unit.
2.Remove the bolts securing the sprocket to the
differential.
3.Lift the differential assembly from the sprocket.
4.Examine the sprocket teeth for wear and
damage, if either are evident renew the sprocket.
Place the sprocket aside until the...

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OVERHAUL 3.Remove the rear upper bevel gear and thrust
washer.
4.Remove the pinion gears and dished washers
along with the cross shaft.
5.Remove the front lower bevel gear and thrust
washer from the front half of the differential unit.
6.Remove the front half of the differential unit from
the vice and clean all components. Examine for
wear or damage, renew if necessary.
Differential pinions - rolling resistance
7.Using soft jaws secure the front half of the
differential unit in the vice....

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OVERHAUL 15.Repeat the procedure to obtain the correct thrust
washer for the front bevel gear, it is not
necessary to fit the rear bevel gear when
checking the front bevel gear rolling resistance.
16.When the thrust washer has been selected for
the front bevel gear, again dismantle the
differential unit and retain the thrust washer and
front bevel gear combination.
Centre differential - Assemble
17.Fit the thrust washer and front bevel gear into
the front half of the differential...

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OVERHAUL
3.Ensuring that the transfer sprocket is fully down,
secure the sprocket to the transfer shaft with the
circlip.
Front and rear cover - main casing - Assemble
1.Ensuring that the joint faces of the front and rear
covers are clean, apply a bead of Dow Corning
732 or a suitable equivalent silicone sealant to
the joint face of the rear cover and evenly spread
the sealant over the face. Do not over apply the
sealant.
2.Fit the front cover, secure with the eleven bolts,
tightening...

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OVERHAUL 6.Clean the sleeve and place to one side.
7.Drive or press the output shaft from the housing.
8.Clean and examine the splines and
speedometer drive gear for wear or damage.
The output shaft can be further dismantled if
either the speedometer drive gear or output shaft
is worn: remove the circlip and slide the gear
from the shaft, retrieve the ball bearing from the
indent in the shaft. Discard the worn component.
NOTE: While the output shaft is removed
from the rear output...

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OVERHAUL Rear output housing (continued)
13.Lever off the dust shield.
14.Prise the oil seal from the housing and discard
the seal.
15.Remove the circlip retaining the bearing.
16.Drive or press the bearing from the housing.
Discard the bearing.
17.Remove any previous sealant from the housing
joint face.
18.Thoroughly clean all components with a suitable
solvent.
19.Examine the housing for damage and wear.
Renew as necessary.
Rear output housing - Assemble
20.Drive or press a new bearing...

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OVERHAUL 4.If necessary the oil catcher can be carefully
pressed from the drive flange, if either a new oil
catcher or bolts are being fitted.
5.Carefully tap the viscous unit out of the housing.
If the original unit is being refitted wipe clean
with a clean cloth.
NOTE: The viscous unit is a sealed
assembly and cannot be further
dismantled, a new unit should be fitted if
the unit is damaged or if the torque to turn is out
of limits.
6.Prise the oil seal out from the front output...