1996 LAND ROVER DEFENDER torque

51REAR AXLE AND FINAL DRIVE
2
REPAIRREV: 05/99 Refit
15.Position axle and fit lower links. Tighten fixings
to
176 Nm (130 lbf/ft).
16.If applicable, fit anti-roll bar links to axleSee
REAR SUSPENSION, Repair, Anti-roll bar
links
.
17.Raise axle and locate road springs.
18.Fit coil spring retaining plates and secure with
fixing bolts.
19.Secure pivot bracket ball joint to axle bracket.
Tighten fixing to
176 Nm (130 lbf/ft).
20.Align propeller shaft to differential drive flange
and tighten fixings to
47 Nm (35 lbf/ft).
21.Reconnect flexible brake hose and axle breather
hose.
22.Refit shock absorbers.
23.Fit road wheels and tighten 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)
24.Remove rear chassis support.
25.Bleed brake system
See BRAKES, Repair,
brake system bleed
.

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.

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.

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.

51REAR AXLE AND FINAL DRIVE
6
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.

51REAR AXLE AND FINAL DRIVE
8
OVERHAUL 86.Before adjusting shim thickness, check pinion
face marking and if it has a plus (+) figure,
subtract that from shim thickness figure obtained
in previous instruction. Alternatively if pinion has
a minus (-) figure, add amount to shim thickness
figure.
87.Adjust shim thickness under pinion inner cup as
necessary, by amount determined in instructions
85 and 86.
88.Recheck pinion height setting instructions 82 to
84. If setting is correct, mean reading on dial
gauge will agree with figure marked on pinion
end face. For example, with an end face marking
of +3, dial gauge reading should indicate that
pinion is 0.003 in (0.0762 mm) below nominal.
89.When pinion setting is satisfactory, temporarily
remove pinion outer bearing.
90.Fit a new collapsable bearing spacer, flared end
outward, to drive pinion and refit outer bearing.
91.Fit pinion oil slinger.
92.Fit oil seal gasket.
93.Fit pinion oil seal, lipped side first, using general
purpose grease or, where available, a
molybdenum disulphide based grease on seal
lip, usingLRT-51-002to drift in seal.
94.Fit coupling flange and plain washer and loosely
fit a new flange nut. SecureLRT-51-003to
coupling flange, using slave fixings.
95.Alternately tighten flange nut and check drive
pinion resistance to rotation until following
figures are achieved, as applicable:
A.Assemblies re-using original pinion bearings:
17,3 to 34,5 kgf cm.
B.Assemblies with new pinion bearings: 34,5 to
46,0 kgf cm.
NOTE: Once the bearing spacer has
started to collapse the torque resistance
build-up is rapid, therefore check
frequently, using a spring balance, to ensure the
correct figures are not exceeded, otherwise a new
collapsable bearing spacer will be required.

REAR AXLE AND FINAL DRIVE
9
OVERHAUL Differential backlash checks
96.Pick up differential unit as left after instruction
52.
97.Fit differential unit and lever unit away from drive
pinion until opposite bearing cup is seated
against housing. Do not tilt unit.
98.Install a dial gauge on casing with its stylus
resting on back face of crown wheel. Zero the
gauge.
99.Lever differential unit to engage crown wheel
teeth in full mesh with drive pinion teeth. Do not
tilt unit.
100.Note total reading obtained on dial gauge.
101.From this figure subtract 0,25 mm to obtain
correct crown wheel backlash when fitted. The
result indicates value of shimming to be fitted
between differential case and bearing cone at
crown wheel side of differential.
102.Fit shim value determined in instruction 101,
taking shims from pack previously determined
during 'Differential bearing adjustment' checks,
instructions 57 to 62LRT-51-500details 1 and 2,
pressLRT-99-002, andLRT-51-504.
103.Fit remaining shims from instruction 101 to
opposite side of differential.LRT-51-501details
1 and 2, pressLRT-99-002, andLRT-51-504.
104.Fit differential unit with shims and bearings to
axle casing, using axle spreaderLRT-51-503
with pegs18G131F.
105.Remove axle spreader.106.Fit bearing caps in their correct position,
referring to relationship markings on caps and on
axle casing.
107.Tighten bearing caps fixings to
135 Nm (100
lbf/ft).
108.Mount a dial gauge on axle casing with stylus
resting on a crown wheel tooth.
109.Prevent drive pinion from rotating and check
crown wheel backlash which must be 0,15 to
0,27 mm. If backlash is not within specified
limits, repeat differential backlash checks,
instructions 96 to 102 looking for possible errors.
110.Fit differential cover and new gasket, coating
both sides of gasket with Hylomar PL 32M or an
equivalent non-setting sealant. Torque load for
fixings is
30 Nm (22 lbf/ft).
111.Reverse instructions 3 to 5 and coat threads of
hub driving member bolts with Loctite 'Studlock'
grade CVX and fit and tighten bolts evenly to
correct torque.
112.Fit rear axle assembly to vehicle
See Repair,
Rear axle
.
113.Replenish differential with recommended
lubricant
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
. After initial axle run,
check oil level and replenish as necessary to
filler/level plug hole.
114.Where major running parts have been replaced
during servicing, it is a recommended practice to
allow axle assembly to 'run in' by avoiding,
where possible, heavy loads and high speeds
during initial running.

REAR AXLE AND FINAL DRIVE
1
SPECIFICATIONS, TORQUE REV: 05/99 TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
REAR AXLE
Pinion housing to axle case 41.......................................................................
Crown wheel to differential case 58................................................................
Differential bearing cap to pinion housing 90..................................................
Differential drive flange to drive shaft 47.........................................................
Bevel pinion nut 129........................................................................................
Lower link to axle 176......................................................................................
Pivot bracket ball joint to axle 176...................................................................