1999 LAND ROVER DEFENDER differential

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.
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FRONT AXLE AND FINAL DRIVE
1
FAULT DIAGNOSIS FAULT DIAGNOSIS
Complaint - Oil leaks
An external leak of lubrication can be caused by a
faulty internal seal. For example, if the seals which
separate the differential from the swivel housings are
faulty and the vehicle is operating or parked on an
embankment, oil may leak across the axle leaving one
swivel with a high level and the opposite swivel and
differential lacking lubrication.
See’Description and Operation’for illustrations of oil
seal locations.
When investigating leaks or checking oil levels, it is
essential that all the lubrication is drained from any
housing with a high level and that the other levels are
checked.
Swivel oil should be checked for signs of grease
leaking from the hub bearings and oil contamination of
the hub grease.
Check that the axle ventilation system is clear, as a
blockage can cause internal pressure to force oil past
the seals.
If the vehicle is driven in deep water with defective oil
seals, water may contaminate the lubricants and when
checked, give a false impression that the housing has
been over filled with oil.
Do not assume that a high oil level is due to over
filling or, that a low level is because of an external
leak.
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FRONT AXLE AND FINAL DRIVE
1
OVERHAUL FRONT DIFFERENTIAL
Service repair no - 54.10.07.
Overhaul
NOTE: The front axle differential, for all
models, is the same as that fitted to the 90
rear axle and can only be serviced as a
complete assemblySee REAR AXLE AND FINAL
DRIVE, Repair. Differential assembly - 90.FRONT HUB
Service repair no - 60.25.14.
Overhaul
1.Remove hub assemblySee FRONT
SUSPENSION, Repair. Front hub bearings.
2.Remove outer bearing.
3.Mark, for reassembly, relationship between hub
and brake disc, if original hub is to be refitted.
4.Remove 5 bolts and separate hub from brake
disc.
5.Drift out grease seal and inner bearing from hub
and discard seal.
6.Drift out inner and outer bearing tracks.
7.Clean hub and drift in inner and outer bearing
tracks.
8.Pack hub inner bearing with recommended
grease and fit to hub.
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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.
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BRAKES
3
REPAIR SENSORS - ABS - REAR WHEELS
Service repair no - 70.65.31
Remove
1.Raise vehicle on a 2 post ramp.
2.Remove both rear wheels.
3.Remove 3 bolts securing each brake disc
backplate to hub assemblies.
4.Remove both back plates.
5.Remove 2 cable ties securing sensor harness to
outer ends of axle.
6.Carefully prise both sensors from hub
assemblies.
7.Release 4 clips securing sensor harness to axle.
8.Release cable tie securing harness to
differential.
9.Release 3 cable ties securing harness to chassis
longitudinal.
10.Disconnect sensor multiplug.
11.Remove harness and sensor assembly.
Refit
12.Position harness and sensor assembly to vehicle
and connect multiplug.
13.Apply grease to both sensors.
14.Carefully fit both sensors to hub assemblies.
15.Secure harness to axle and differential with
cable ties.
16.Secure harness to axle with clips.
17.Secure harness to chassis with cable ties.
18.Fit both back plates to hub assemblies and
secure with bolts.
19.Fit rear wheels and tighten to130 Nm (95 lbf.ft)
.
20.Lower vehicle.
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CHASSIS AND BODY
1
REPAIR PANEL - UNDERBELLY - FRONT AND CENTRE
Service repair no - 76.10.50
Remove
1.Raise vehicle on 4 post ramp.
2.Mark front propellor shaft and front differential
flanges for reassembly.
3.Remove 4 bolts and release propellor shaft from
front differential.
4.Remove 12 bolts securing front and centre
underbelly panels.
5.Remove front and centre underbelly panels.
Refit
6.Position front and centre underbelly panels.
7.Fit and tighten bolts securing front and centre
underbelly panels.
8.Position front propellor shaft to differential and
tighten bolts to48 Nm (35 lbf.ft).
9.Lower vehicle.CUBBY BOX
Service repair no - 76.25.04
Remove
1.Open cubby box lid and remove 2 caps
concealing rear fixing bolts.
2.Remove bolts securing rear of cubby box.
3.Open flap concealing front fixing bolts.
4.Remove bolts securing front of cubby box.
5.Remove cubby box.
Refit
6.Fit cubby box to vehicle.
7.Fit bolts securing front of cubby box and
reposition flap.
8.Fit bolts securing rear of cubby box.
9.Fit caps over bolts.
10.Close cubby box lid.
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