1996 LAND ROVER DEFENDER lock

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
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.

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
7
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.

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.