1999 LAND ROVER DEFENDER Workshop Manual

54FRONT AXLE AND FINAL DRIVE
2
OVERHAUL
9.With lip side leading fit new seal to hub using
special toolLST 137seal replacer and drift18G
134. Drive in seal flush with rear face of hub.
Apply grease between seal lips.
10.Fit brake disc to hub, lining up to marks made
during dismantling. Applying Loctite 270, fit
retaining bolts. Tighten to73 Nm (54 lbf/ft).
11.Grease and fit outer bearing to hub.
12.Fit hub assemblySee FRONT SUSPENSION,
Repair. Front hub bearings.
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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.
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54FRONT AXLE AND FINAL DRIVE
4
OVERHAUL 12.Examine all components, in particular, inner and
outer track, cage balls and bearing surfaces for
damage and excessive wear.
13.Maximum acceptable end-float on assembled
joint 0,64mm. Renew if worn or damaged.
Lubricate with a recommended oil during
assembly.
Fit constant velocity joint to axle
14.Fit collar and a new circlip.
15.Engage constant velocity joint on axle shaft
splines and using a soft mallet, drive joint in fully.
Renew stub axle, thrust ring, oil seal and bearing
16.Drill and chisel off thrust ring taking care to avoid
damaging stub axle.
17.Remove bearing and oil seal using special tool
TRT-37-004and slide hammerLRT-99-004.
Ensure lip of tool locates behind bearing to to
drive it out.
18.Repeat instruction for removal of oil seal.
19.Lubricate seal and lip with EP90 oil and with
cavity side leading press in a new oil seal using
special toolLRT-54-004.
20.Using special toolLRT-54-005, fit bearing with
its part number visible when fitted, and flush with
end face of stub axle.
21.Press fit a new thrust ring onto stub axle.
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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
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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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57 - STEERING
CONTENTS
Page
REPAIR
STEERING COLUMN - UPPER - Td5 1.................................................................
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STEERING
1
REPAIR STEERING COLUMN - UPPER - Td5
Service repair no - 57.40.01
Remove
1.Ensure road wheels and steering wheel are set
in the straight ahead position.
2.Loosen 2 clips securing air inlet pipe between
turbo and inlet air filter.
3.Remove air inlet pipe.
4.Mark relationship between the upper steering
column and the lower steering column universal
joint.
5.Remove bolt securing upper column to lower
column universal joint.
6.Remove steering colum nacelle.See this
Section.
7.Remove instrument pack.See
INSTRUMENTS, Repair.
8.Disconnect 3 column switch multiplugs.
9.Loosen column switch clamping screw.
10.Remove column switch assembly from steering
column.
11.Disconnect 4 Lucars from rear of ignition switch.
NOTE: Take note of Lucars correct fitted
position. Details can also be found in the
Electrical Reference Library.
12.Remove passive coil.See ELECTRICAL,
Repair.
13.Drill out 2 shear bolts securing ignition barrel to
column.
14.Remove ignition barrel.
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