1996 LAND ROVER DEFENDER differential

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
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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.

51REAR AXLE AND FINAL DRIVE
4
OVERHAUL
37.UsingLRT-51-500and pressLRT-99-002,
remove inner bearing cone from pinion.
INSPECTION
38.Examine all components for obvious wear or
damage.
39.Bearing cones must be a press fit on their
locations, except drive pinion flange and bearing
which is a slide fit.
40.The crown wheel and pinion are supplied as a
matched pair and must not be interchanged
separately. A new crown wheel and pinion
matched pair may be fitted to an original gear
carrier casing if sound. original crown wheel and
pinion, if sound, may be fitted into a replacement
casing.
41.The two parts of differential unit casing are
matched and must not be replaced separately.
42.Discard and renew all thrust washers.
43.Differential housings with worn thrust washer
seatings must be replaced as a pair.
44.Examine differential case to crown wheel joint
face for burrs and damage which could lead to
crown wheel run-out when fitted.ASSEMBLE
Differential
45.Fit differential lower wheel and thrust washer to
differential case. See illustration following
instruction 23.
46.Fit dished thrust washers.
47.Fit cross-shaft and pinions.
48.Fit differential upper wheel and thrust washer.
49.Fit differential upper case lining-up marks.
50.Secure assembly with bolts using Loctite
'Studlock' grade CVX on threads and tighten
evenly and diametrically to
95 Nm (70 lbf/ft).
51.Fit crown wheel to differential casing. Use Loctite
'Studlock' grade CVX on fixing bolt threads and
tighten to correct torque.
52.Press on differential roller bearing cones less
shim washers, usingLRT-51-504, and leave to
one side until required for instruction 96.
53.Fit bearing cups to differential.
54.Fit differential unit and bearings to gear carrier
casing, and rotate unit to centralize bearings. Do
not fit bearing caps.

REAR AXLE AND FINAL DRIVE
5
OVERHAUL
55.Position a suitable dial gauge indicator on casing
with stylus registering on back face of crown
wheel.
56.Rotate differential and check total indicated
run-out on crown wheel back face. This must not
exceed 0,05 mm. If run-out is excessive, check
mating faces for dirt and damage; if necessary,
select a new radial position for crown wheel.
When satisfactory, continue with following check.
Differential bearing adjustment
57.Insert two levers between casing and differential
unit at one side.
58.Move differential unit fully to one side of casing;
do not tilt unit.
59.Rotate differential unit to settle bearings,
continue to lever differential to side, then zero
dial gauge indicator.
60.Lever assembly fully to other side of casing,
rotate unit to settle bearings, then note total
indicator reading.
61.Add 0,127 mm, for bearing pre-load, to total
noted in preceding instruction. The sum is then
equal to nominal value of shims required for
differential bearings. Shims are available in
range 0,07 mm, 0,12 mm, 0,25 mm and 0,76
mm. Select total value of shims required.
62.Remove differential unit and bearings and place
aside. Do not fit shim washers until subsequent
'Differential backlash' checks have been made,
instructions 96 to 102.Fit drive pinion
63.Select shim washers of same thickness value as
those removed from under pinion inner cup,
instruction 35, and place ready for fitting.
64.Position outer bearing replacerLRT-51-505,
detail 2, and outer bearing cup on press
LRT-99-502.
65.Locate assembly into pinion housing nose.
66.Place selected shim washers on to inner bearing
cup seating.
67.Position inner bearing cup in casing.
68.Position inner bearing replacerLRT-51-505,
detail 1, ontoLRT-99-502and secure with fixing
nut.
69.Hold still centre screw and turn butterfly lever to
draw in bearing cups.

51REAR AXLE AND FINAL DRIVE
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OVERHAUL
70.Press inner bearing cone onto drive pinion using,
LRT-51-502details 1 and 2 and press
LRT-99-002.
71.Position pinion and bearing in casing; omit
collapsable spacer at this stage.
72.Fit outer bearing cone onto pinion.
73.Fit coupling flange and plain washer and loosely
fit flange nut.
74.Tighten coupling flange locknut to remove
end-float from pinion.
75.Rotate pinion to settle bearings and slowly
tighten flange locknut. Use a spring balance to
obtain a torque resistance of 11 Kgf/cm (18
lbf/in) to rotate pinion.
Drive pinion markings
76.Check that serial number marked on pinion end
face matches that marked on crown wheel.
77.The markings on end face adjacent to serial
number are of no significance during servicing.
78.The figure marked on end face opposite to serial
number indicates, in thousandths of an inch,
deviation from nominal required to correctly set
pinion. A pinion marked plus (+) must be set
below nominal, a minus (-) pinion must be set
above nominal. An unmarked pinion must be set
at nominal.
79.The nominal setting dimension is represented by
setting gauge block18G191PorLRT-54-503,
which is referenced from pinion end face to
bottom radius of differential bearing bore. The
latter gauge is illustrated following instruction 85.
Drive pinion adjustment
80.Ensure that pinion end face is free of raised
burrs around etched markings.
81.Remove keep disc from magnetized base of dial
gauge tool18G191.
82.Place dial gauge and setting gauge18G191Por
LRT-54-503on a flat surface and zero dial
gauge stylus on to setting gauge.

REAR AXLE AND FINAL DRIVE
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OVERHAUL
83.Position dial gauge centrally on pinion end face
with stylus registering on lowest point on one
differential bearing bore. Note dial gauge
deviation from zeroed setting.
84.Repeat on other bearing bore. Add together
readings, then halve sum to obtain mean
reading. Note whether stylus has moved up or
down from zeroed setting.
Example 1
Reading obtained LH side.............. + 0.1524mm
Reading obtained RH side............. - 0.0762mm
Add + 0.1524mm - 0.0762mm = + 0.0762mm
Divide by 2 (0.0762 divided by 2)= 0.0381mm
Therefore subtract 0.0381mm from shim thickness
behind pinion inner bearing track.
Example 2
Reading obtained LH side............. + 0.1524mm
Reading obtained RH side............ - 0.2032mm
Add + 0.1524mm - 0.2032mm = + 0.0508mm
Divide by 2 (0.0508 divided by 2)= 0.0254mm
Therefore add 0.0254mm from shim thickness behind
pinion inner bearing track.
85.Where stylus has moved down (85a), amount is
equivalent to thickness of shims that must be
removed from under pinion inner cup to bring
pinion down to nominal position. Where stylus
has moved up (85b), amount is equivalent to
additional thickness of shims required to bring
pinion up to nominal position.
Illustration A. Using setting gauge18G191P.
Illustration B. Using universal setting block
LRT-54-503. This setting block has 3 setting heights.
Ensure that height marked 30.93 mm is used for this
differential.