1996 LAND ROVER DEFENDER Workshop Manual

REAR AXLE AND FINAL DRIVE
3
REPAIR REAR HUB ASSEMBLY - 90
Service repair no - 64.15.01
Remove
1.Place rear axle onto axle stands and remove
road wheel.
2.Release brake hose clips and remove brake
caliper bolts. Secure to one side.
WARNING: Take care not to kink brake
hose.
3.Remove 5 bolts and withdraw axle shaft.
4.Remove joint washer.
5.Bend back lock washer tabs.
6.Remove locknut and lock washer.
7.Remove hub adjusting nut.
8.Remove spacing washer.
9.Remove hub and brake disc assembly complete
with bearings.
Rear hub components - 90
1.Axle shaft.
2.Axle shaft joint washer.
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 AXLE AND FINAL DRIVE
4
REPAIRREV: 05/99 Refit
10.Clean stub axle.
11.Fit hub assembly to stub axle.
12.Fit spacing washer.
13.Fit hub adjusting nut. Tighten to
50 Nm (37
lbf/ft).
Ensure hub is free to rotate with no
bearing play. Back off adjusting nut 90°and
tighten to
10 Nm (7 lbf/ft).
14.Fit a new lock washer.
15.Fit locknut. Tighten to
50 Nm (37 lbf/ft).
16.Tab over lock washer to secure adjusting nut
and locknut.
17.Using a new joint washer fit axle shaft to hub.
Tighten bolts to
65 Nm (48 lbf/ft).
18.Fit brake caliper. Tighten bolts to82 Nm (61
lbf/ft).
Secure brake pipes to axle casing.
19.Fit road wheel, remove axle stands and tighten
road wheel nuts to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
20.Operate footbrake to locate brake pads before
driving vehicle.

REAR AXLE AND FINAL DRIVE
5
REPAIR REAR HUB ASSEMBLY - 110/130
Service repair no - 64.15.01
Remove
1.Loosen rear wheel nuts, jack up vehicle and
lower onto axle stands. Remove road wheel.
2.Release brake pipe clips, remove brake caliper
and brake disc shield bolts. Secure to one side.
WARNING: Take care not to kink brake
hose.3.Lever off dust cap.
4.Remove circlip from driveshaft.
5.Remove 5 bolts and withdraw driving member
and joint washer.
6.Bend back lock washer tabs.
7.Remove locknut and lock washer.
8.Remove hub adjusting nut.
9.Remove spacing washer.
10.Remove hub and brake disc assembly complete
with bearings.
Hub components
1.Dust cap.
2.Drive shaft circlip.
3.Drive member.
4.Drive member joint washer.
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 AXLE AND FINAL DRIVE
6
REPAIRREV: 05/99 Refit
11.Clean stub axle and drive shaft and fit hub
assembly to axle.
12.Fit spacing washer.
13.Fit hub adjusting nut. Tighten to
50 Nm (37
lbf/ft).
Ensure hub is free to rotate with no
bearing play.
14.Back off adjusting nut 90°and tighten to
10 Nm
(7 lbf/ft).
15.Fit a new lock washer.
16.Fit locknut. Tighten to
50 Nm (37 lbf/ft).
17.Tab over lock washer to secure adjusting nut
and locknut.
18.Fit a new joint washer to driving member and fit
member to hub. Tighten bolts to
65 Nm (48
lbf/ft).
19.Fit circlip and dust cap.
20.Fit brake disc shield and brake caliper. Tighten
bolts to
82 Nm (61 lbf/ft).
21.Bleed brake systemSee BRAKES, Repair,
Brake system bleed
.
22.Fit road wheel, remove axle stands and tighten
road wheel nuts to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
23.Operate footbrake to locate brake pads before
driving vehicle.

REAR AXLE AND FINAL DRIVE
7
REPAIR DIFFERENTIAL ASSEMBLY - 90
Service repair no - 51.15.01
Remove
1.Using suitable container, drain axle oil.
2.Mark differential and propeller shaft flanges to
facilitate reassembly.
3.Remove 4 bolts and disconnect propeller shaft
from differential. Tie aside.
4.Remove 5 hub drive member bolts and withdraw
axle half shafts sufficiently to disengage from
differential unit.
5.Remove 10 nuts securing differential to axle
case.
6.Withdraw differential unit.
NOTE: The differential unit can only be
serviced as a complete assembly with
matching drive pinion. For advice ring
Land Rover Service Department.Refit
7.Ensure mating faces are clean and apply a bead
of RTV sealant to axle case.
8.Support differential unit and position on axle
casing.
9.Secure with self locking nuts and tighten to
40
Nm (30lbf/ft).
10.Align marks on flanges and secure propeller
shaft to differential. Tighten bolts to
48 Nm (35
lbf/ft).
11.Refit half shafts, using new drive member
gaskets. Tighten bolts to
65 Nm (48 lbf/ft).
12.Refill axle oil with approved lubricantSee
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
.

REAR AXLE AND FINAL DRIVE
1
OVERHAUL DIFFERENTIAL ASSEMBLY - 110/130
Service repair no - 51.15.07
Overhaul
1.Drain off differential lubricating oil, and refit plug.
2.Remove rear axle assembly from vehicle
See
Repair, Rear axle
3.Remove hub driving member fixings.
4.Withdraw driving member and axle shaft
sufficiently to disengage differential.
5.Repeat instruction 4 for other axle shaft.
6.Remove fixings and support strip at differential
cover and withdraw cover and joint washer.
7.Note relationship marking on bearing caps and
axle casing to ensure correct refitting.
8.Remove fixings and withdraw differential bearing
caps.
9.Clean out and examine spreader tool pegholes
provided in gear casing face; ensure that holes
are free from dirt and burrs and damage.
10.Ensure that turnbuckle adjuster is free to turn.
Using axle spreader 18G31C
11.Fit axle spreader to engage peg holes.
(Spreader18G131C, Adaptor pegs18G131F)
12.Using a spanner, turn adjuster until all free play
between spreader and casing is taken up,
denoted by adjuster becoming stiff to turn.
13.Check that side members of spreader are clear
of casing.
14.Stretch casing, rotating adjuster by one flat at a
time, until differential assembly can be levered
out. Do not lever against spreader; use suitable
packing under levers to avoid damage to casing.

51REAR AXLE AND FINAL DRIVE
2
OVERHAUL
CAUTION: To prevent permanent damage
to the gear carrier case, it must not be
over-stretched. Each flat on the turnbuckle
is numbered to enable a check to be made on the
amount turned. The maximum stretch permitted is
0,30 mm, equivalent to three flats.
15.Ease off adjuster and remove spreader.
Using axle compressor LRT-51-503 (GKN 131)
16.Place tool on to differential casing, as illustrated,
with weld seam uppermost. Ensure that plates
rest squarely on differential machined surface
and end bars butt against edges of casing.
17.Tighten adjusting nuts by hand only, until all
slack is taken up.
18.Continue to tighten both nuts alternately with a
spanner, one flat at a time, to a maximum of
three flats.
19.Carefully lever-out differential assembly.
Dismantle differential
20.Add alignment marks between crown wheel and
differential case for reassembly purposes, then
remove fixings and withdraw crown wheel.
21.Note alignment markings on two differential
casings to ensure correct refitting, then remove
fixings.
22.Lift off upper case.
23.Withdraw upper differential wheel and thrust
washer.
24.Lift out cross-shaft and pinions.

REAR AXLE AND FINAL DRIVE
3
OVERHAUL
25.Withdraw four dished thrust washers.
26.Withdraw lower differential wheel and thrust
washer.
27.Remove differential bearing cones using
LRT-51-500, adaptors 1 and 2 and press
LRT-99-002.
28.Withdraw shim washers fitted between bearing
cones and differential casings.
Remove final drive pinion
29.UsingLTR-51-003to prevent coupling flange
from rotating, remove flange locknut and plain
washer.
30.Support drive pinion and remove coupling flange
by tapping with a hide hammer.
31.Withdraw drive pinion toger with inner bearing
cone.
32.Withdraw and discard collapsable bearing
spacer.
33.Withdraw oil seal, gasket and oil thrower.
34.Withdraw outer bearing cone.
35.UsingLRT-51-502, extract pinion inner bearing
cup and shim washers from casing. Note shim
washer thickness. .
36.Extract pinion outer bearing cup from casing
usingLRT-51-502.