1999 LAND ROVER DEFENDER washer

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
ProCarManuals.com

FRONT AXLE AND FINAL DRIVE
1
REPAIR 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 linkSee 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 linksSee FRONT
SUSPENSION, Repair. Anti-roll bar links.
18.Fit propeller shaft. Tighten bolts to47 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 to82 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 to197 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)
ProCarManuals.com

FRONT AXLE AND FINAL DRIVE
3
OVERHAUL FRONT STUB AXLE, CONSTANT VELOCITY JOINT
AND SWIVEL PIN HOUSING
Service repair no - 60.15.43.
Remove stub axle, axle shaft and constant
velocity joint.
1.Remove front hub assemblySee FRONT
SUSPENSION, Repair. Front hub bearings.
2.Drain swivel pin housing and refit plug.
NOTE: On later vehicles the swivel pin
housing is filled with grease for life, the
level and drain plugs being deleted.
3.Remove 6 bolts retaining stub axle to swivel
housing.
4.Remove mud shield.
5.Remove stub axle and joint washer.
6.Wthdraw axle shaft and constant velocity joint
from axle casing.
Remove constant velocity joint from axle shaft
7.Hold axle shaft firmly in a soft jawed vice.
8.Using a soft mallet drive constant velocity joint
from shaft.
9.Remove circlip and collar from axle shaft.
Constant velocity joint
10.Mark positions of constant velocity joint, inner
and outer race and cage for reassembly.
11.Swivel cage and inner race to remove balls.
ProCarManuals.com

FRONT AXLE AND FINAL DRIVE
5
OVERHAUL Swivel pin housing
22.Remove bolts securing oil seal retaining plate
and joint washer. Release assembly from swivel
pin housing.
NOTE: Removal of oil seal and retaining
plate is achieved when swivel bearing
housing is removed.
23.Remove 2 bolts, retaining lower swivel pin to
housing.
24.Remove brake disc shield bracket.
25.Tap lug to remove lower swivel pin and joint
washer.
26.Remove two bolts retaining brake hose bracket
and top swivel pin.
27.Remove bracket, top swivel pin and shims.
28.Remove swivel pin housing while retrieving
lower and upper bearings.
Swivel bearing housing
29.Remove lower bearing track from swivel bearing
housing.
NOTE: Use upper bearing opening to gain
access to lower bearing track.
30.Remove 7 bolts retaining swivel bearing housing
to axle case.
31.Remove inner oil seal from back of housing.
32.Remove top bearing track from swivel bearing
housing.
NOTE: Use lower bearing opening to gain
access to upper bearing track.
33.If worn, pitted or damaged, renew housing.
34.Fit upper and lower bearing tracks into swivel
bearing housing.
CAUTION: Ensure bearing tracks are fitted
square or damage could occur.
35.With seal lips trailing, fit swivel housing inner oil
seal into rear of housing. Grease seal lips.
Fit swivel pin housing
36.Coat swivel bearing housing to axle casing bolts
with Loctite 270 or equivalent.
37.Coat both sides of joint washer with a sealing
compound. Position swivel bearing housing to
axle mating face.Swivel assembly components
1.Swivel pin housing
2.Top swivel pin and brake hose bracket
3.Upper and lower swivel pin bearings
4.Shim
5.Retaining plate and washer
6.Oil seal
7.Joint washer
8.Swivel bearing housing
9.Joint washer
10.Lower swivel pin
11.Mudshield bracket
12.Swivel housing inner oil seal
ProCarManuals.com

54FRONT AXLE AND FINAL DRIVE
6
OVERHAUL 38.Place retaining plate, joint washer and oil seal
over axle flange ready for assembly.
39.Fit swivel bearing housing to axle flange with 7
bolts. Tighten to73 Nm (54 lbf/ft).
40.Grease and fit upper and lower swivel pin taper
roller bearings.
41.Position swivel pin housing over swivel bearing
housing.
42.Coat joint washer both sides with sealing
compound and position on lower swivel pin.
43.Loosely fit brake shield bracket plus lower swivel
pin with lug outboard to swivel pin housing.
44.Loosely fit top swivel pin plus existing shims and
brake hose bracket to swivel pin housing.
45.Apply Loctite 270 or equivalent to lower swivel
pin bolts.25 Nm (18 lbf/ft),bend over lock tabs.
46.Tighten top swivel pin bolts to65 Nm (48 lbf/ft).
Check and adjust preload on bearings
NOTE: Swivel housing oil seal and axle
should not be fitted.
47.Attach a spring balance to track rod ball joint
bore and pull balance to determine effort
required to turn swivel pin housing.
Resistance, once initial inertia has been
overcome, should be1.16 to 1.46 kg.Adjust by
removing or adding shims to top swivel pin.
48.When setting is correct remove top swivel bolts,
apply Loctite 270 or equivalent. Refit bolts and
tighten to65 Nm (48 lbf/ft),and bend over lock
tabs.
49.Apply recommended grease between lips of
swivel oil seal.50.Fit oil seal, joint washer and retaining plate with
7 bolts and spring washers. Tighten to11 Nm (8
lbf/ft).
51.Fit tie rod and drag link and secure with new
cotter pins. Tighten fixing to40 Nm (30 lbf/ft).
52.Fit brake disc shield.
53.Loosely fit lock stop bolt and nut.
54.Apply a recommended grease between lips of
swivel housing oil seal.
55.Secure oil seal with retaining plate and securing
bolts. Tighten to11 Nm (8 lbf/ft).
56.Fit track-rod and drag link and secure with new
cotter pins.
57.Loosely fit lock stop bolt for later adjustment.
58.Fit brake disc shield.
Fit driveshaft and stub axle
59.Insert axle shaft, and when differential splines
are engaged, push assembly in fully.
CAUTION: Take care not to damage axle
shaft oil seals.
60.Place a new joint washer in position on swivelpin
housing to stub axle mating face. Coat threads
of stub axle bolts with Loctite 270.
61.Fit stub axle with flat at 12 O’clock position.
CAUTION: Ensure that constant velocity
joint bearing journal is butted against
thrust ring on stub axle before stub axle is
secured.
62.Place mud shield in position and secure stub
axle to swivel pin housing with 6 bolts and
tighten evenly to65 Nm (48 lbf/ft).
63.Fit brake jump hoses to brake jump hose
bracket.
64.Fit complete front hub assemblySee FRONT
SUSPENSION, Repair. Front hub bearings.
65.Check swivel pin housing oil drain plug is fitted.
66.Fill swivel assembly to correct level, with new oil
See MAINTENANCE , Under vehicle
maintenance.
NOTE: On later vehicles fill swivel pin
housing with 0.33 Litres of Molytex EP 00
grease.
67.Set steering lock stop boltsSee STEERING,
Adjustment. Steering lock stops.
ProCarManuals.com

60FRONT SUSPENSION
2
REPAIR 12.Knock back staking and using a suitable socket,
remove and discard hub nut.
13.Remove washer from hub.
14.Remove hub and brake disc assembly complete
with bearings.
15.Remove outer bearing and spacer from hub.
16.Remove grease seal and inner bearing from
hub.
17.Remove inner and outer bearing tracks from
hub.
Refit
18.Clean hub and bearing locations.
19.Fit inner and outer bearing tracks to hub.
20.Pack inner bearing with grease and fit to hub.
21.Fit new seal flush with rear face of hub using
LRT-54-003andLRT-99-003.
22.Clean stub axle.
23.Pack outer bearing with grease, fit spacer and
bearing to hub.
24.PositionLRT-54-019over hub nut threads on
axle casing.
25.Fit hub assembly to stub axle, remove
LRT-54-019.
26.Fit washer and new hub nut and tighten to30
Nm (22 lbf.ft).
27.Rotate and push/pull hub to setle bearings.
Tighten hub nut to210 Nm (150 lbf.ft).
28.To check drive shaft end float, mount a dial
gauge using bracketLRT-99-503to driving
member bolt hole.
29.Ensure dial gauge is contacting hub nut face.
30.Move drive shaft in and out noting dial gauge
reading.31.If end float is present refer to table for correct
spacer and change spacer as necessary.
32.When no end float is evident, remove the dial
gauge and mounting bracket.
33.Stake the hub nut.
34.Clean hub and axle shaft faces.
35.Fit new driving member gasket.
36.Position driving member to hub and tighten new
bolts to65 Nm (48 lbf.ft).
37.Fit original shim(s) to drive shaft and secure with
circlip.
38.Position brake caliper to hub, align fixings, fit
bolts and tighten to82 Nm (60 lbf.ft).
39.Remove plugs from brake pipe connections.
40.Connect brake pipe union to jump hose and
tighten union.
CAUTION: Use 2 spanners when
tightening or loosening unions.
41.Remove brake hose clamp from jump hose.
42.Bleed brake system.See BRAKES,
Adjustment.
43.Fit road wheel, remove axle stand and tighten
wheel nuts to130 Nm (95 lbf.ft).
44.Operate foot brake to locate brake pads before
taking vehicle on road.
ProCarManuals.com

REAR SUSPENSION
1
REPAIR BEARING - REAR HUB
Service repair no - 64.15.14
Remove
1.Raise rear of vehicle.
WARNING: Support on safety stands.
2.Remove rear road wheel.
3.Remove 2 bolts securing brake caliper to hub.
4.Release caliper from disc and tie aside.
5.Remove 5 bolts securing axle shaft.
6.Remove axle shaft and discard gasket.
7.Knock back staking, and using a suitable socket,
remove and discard stake nut.
8.Remove hub nut washer.
9.Remove hub and brake disc assembly complete
with bearings.
10.Remove outer bearing and spacer from hub.
11.Remove grease seal and inner bearing from
hub.
12.Remove inner and outer bearing tracks from
hub.
Refit
13.Clean hub and bearing locations.
14.Fit inner and outer bearing tracks to hub.
15.Pack inner bearing with grease and fit to hub.
16.Fit new grease seal flush with rear face of hub
usingLRT-54-003andLRT-99-003.
17.Clean stub axle.
18.Pack outer bearing with grease, fit spacer and
bearing to hub.
19.Fit hub assembly to stub axle, remove
LRT-54-019.
20.Fit washer and new hub nut and tighten to30
Nm (22 lbf.ft).
21.Rotate and push/pull hub to settle bearings.
Tighten hub nut to210 Nm (150 lbf.ft).
22.To check drive shaft end float, mount a dial
gauge using bracketLRT-99-503to driving
member bolt hole.
23.Ensure dial gauge is contacting hub nut face.
24.Move drive shaft in and out noting dial gauge
reading.
ProCarManuals.com

BRAKES
5
REPAIR SERVO ASSEMBLY
Service repair no - 70.50.01
Remove
Before starting, refer to general brake service
practice.See Adjustment.
NOTE: The non-return valve and grommet
are the only serviceable components. In
event of failure or damage, fit a new unit.
1.Remove master cylinder.See this Section.
2.Release vacuum hose from servo.
3.Disconnect brake light switch Lucars.
4.Remove 3 screws securing closing panel to
lower’A’post.
5.Release closing panel sufficient to gain access
to brake pedal return springs.
6.Release 2 brake pedal return springs from brake
pedal.
7.Remove blanking grommets from either side of
pedal box.
8.Remove split pin and clevis pin securing servo
push rod to brake pedal.
9.Remove 2 nuts securing servo to pedal box.
10.Remove servo assembly and rubber washer
from pedal box.
ProCarManuals.com