1999 LAND ROVER DEFENDER shaft

REAR AXLE AND FINAL DRIVE
5
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 to40
Nm (30lbf/ft).
10.Align marks on flanges and secure propeller
shaft to differential. Tighten bolts to48 Nm (35
lbf/ft).
11.Refit half shafts, using new drive member
gaskets. Tighten bolts to65 Nm (48 lbf/ft).
12.Refill axle oil with approved lubricantSee
LUBRICANTS, FLUIDS AND CAPACITIES,
Information. Recommended lubricants and
fluids.
ProCarManuals.com

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 vehicleSee
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 peg holes
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 compressor LRT-51-503
11.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.
12.Tighten adjusting nuts by hand only, until all
slack is taken up.
13.Continue to tighten both nuts alternately with a
spanner, one flat at a time, to a maximum of
three flats.
14.Carefully lever-out differential assembly.
ProCarManuals.com

51REAR AXLE AND FINAL DRIVE
2
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
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.
ProCarManuals.com

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 to95 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.
ProCarManuals.com

51REAR AXLE AND FINAL DRIVE
10
OVERHAUL REAR HUB ASSEMBLY - 90
Service repair no - 64.15.13.
1.Remove rear hubSee 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.
ProCarManuals.com

REAR AXLE AND FINAL DRIVE
13
OVERHAUL REAR STUB AXLE - 110/130
Service repair no - 64.15.22
STUB AXLE COMPONENTS
1.Rear axle shaft
2.Stub axle to axle casing bolt
3.Mud shield
4.Stub axle
5.Stub axle joint washer
6.Axle caseOverhaul
1.Remove hub assemblySee REAR
SUSPENSION, Repair. Rear hub bearing.
2.Remove 6 bolts from stub axle to axle casing.
3.Remove mud shield.
4.Remove stub axle and joint washer.
5.Remove rear axle shaft from axle casing.
Renew rear stub axle oil seal
6.Remove and discard oil seal. Lubricate seal and
lip EP90 oil. Using special toolLRT-51-004
(LST138) fit new seal lip side trailing so that seal
is flush with rear face of stub axle.
Refit
7.Fit new joint washer, stub axle and mud shield.
Tighten bolts to65 Nm (48 lbf/ft).
8.Fit rear axle shaft, avoid damaging stub axle
seal.
9.Refit hub assemblySee REAR SUSPENSION,
Repair. Rear hub bearing.
ProCarManuals.com

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

54FRONT AXLE AND FINAL DRIVE
2
DESCRIPTION AND OPERATION Lubrication
The differential, swivel pin housing and wheel hubs
are individually 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.
ProCarManuals.com