1996 LAND ROVER DEFENDER wheel

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
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.

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.

51REAR AXLE AND FINAL DRIVE
10
OVERHAUL REAR HUB ASSEMBLY - 90
Service repair no - 64.15.13.
1.Remove rear hub
See Repair, Rear hub
assembly
.
2.Remove outer bearing.
3.Mark, for reassembly, position of hub to brake
disc.4.Remove 5 bolts and separate hub from brake
disc.
WARNING: A maximum of two road wheel
retaining studs can be renewed. Should
more studs be unserviceable fit new hub
with studs.
5.Remove grease seal and inner bearing from
hub.
6.Remove inner and outer bearing tracks.
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.

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...................................................................

FRONT AXLE AND FINAL DRIVE
1
DESCRIPTION AND OPERATION DESCRIPTION
The welded steel front axle casing houses a separate
spiral bevel type differential unit, which is off-set to the
right of the vehicle centre line. The differential unit
drives the front wheels via the axle shafts and
constant velocity joints which are totally enclosed in
the spherical and swivel housings.The front wheels are pivoted on tape roller bearings at
the top and bottom of the swivel housing. The wheel
hubs on all axles are supported by two taper bearings
and driven by drive flanges which are splined to the
one piece, stub shaft/constant velocity joint.
Front axle hub and swivel housing
1.Axle casing
2.Ventilation pipe
3.Axle shaft
4.Wheel studs and hub
5.Stub axle
6.Wheel bearings
7.Inner and outer hub seals
8.Axle shaft seal
9.Hub lock plate, thrust washer and nuts
10.Brake disc
11.Drive flange
12.Shim washer and circlip13.Dust cap
14.Constant velocity joint/shaft
15.Thrust collar for CV joint
16.Roller bearing
17.Spacer
18.Circlip
19.Top and bottom swivel taper bearing
20.Top and bottom swivel pins
21.Spherical housing, seal and retainer
22.Swivel housing
23.Constant velocity shaft seal

54FRONT AXLE AND FINAL DRIVE
2
DESCRIPTION AND OPERATION Lubrication
The differential, swivel pin housing and wheel hubs
are indiviudally lubricated and separated by oil seals
(7) and (8), see J6267A, to prevent oil transfer across
the axle when the vehicle is traversing steep inclines.
The wheel bearings are lubricated with grease and the
swivel housing and differential with oil. On later
vehicles, identified by having only a filler plug in the
swivel housing, grease is used to lubricate the
housing assembly,
Ventilation
Ventilation of the differential is through a plastic pipe
(2) which terminates at a high level in the vehicle axle.
The swivel housings ventilate through axle shaft oil
seals (8) into the differential and the hub bearings
vent via the oil seals into the swivel housing.

FRONT AXLE AND FINAL DRIVE
1
REPAIR REV: 05/99 FRONT AXLE ASSEMBLY
Service repair no - 54.10.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
axle when lowering or repositioning axle.
1.Support chassis front.
2.Remove road wheels.
3.Support axle weight with hydraulic jack.
4.Remove radius arms to chassis frame nuts.
5.Disconnect steering damper from track rod.
Using a extractor remove track rod links from
swivel pin arms.
6.Remove four nuts and bolts securing radius
arms to axle bracket.
7.Remove radius arms.
8.Remove bolts securing brake hose brackets .
Refit bolts to prevent oil leakage.
9.Remove bolts from brake calipers and tie to one
side.
10.Remove nuts and washers securing shock
absorbers to axle.
11.Disconnect drag link from swivel pin housing
arm.
12.Remove two nuts and bolts securing panhard
rod to axle bracket. Lift rod clear of axle.
13.Mark for reassembly drive shaft flanges.
Remove four nuts and bolts, tie propeller shaft to
one side.
14.Release axle ventilation pipe banjo and lower
axle assembly. Remove road springs.
15.Disconnect anti-roll bar link
See FRONT
SUSPENSION, Repair, Anti-roll bar ball
.
16.Remove axle assembly.
Refit
17.Position axle under vehicle, supporting left side
of axle, and fit anti-roll bar links
See FRONT
SUSPENSION, Repair, Anti-roll bar links
.
18.Fit propeller shaft. Tighten bolts to
47 Nm (35
lbf/ft).
19.Fit panhard rod to axle bracket. Tighten bolts to
88 Nm (65 lbf/ft).
20.Fit drag link to swivel pin arm. Tighten fixings to
40 Nm (30 lbf/ft).
21.Fit shock absorbers to axle.
22.Fit brake calipers. Tighten bolts to
82 Nm (60
lbf/ft).
23.Tighten upper swivel pin bolts to78 Nm (58
lbf/ft).
24.Fit radius arms to axle brackets. Tighten bolts to
197 Nm (145 lbf/ft).
25.Fit steering damper to track rod.
26.Fit radius arms to chassis side member. Tighten
fixings to
197 Nm (145 lbf/ft).
27.Tighten track rod end to40 Nm (30 lbf/ft)and fit
new split pin.
28.Remove chassis supports, 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)