1999 LAND ROVER DEFENDER washer

TRANSFER GEARBOX
11
REPAIR
3.Remove screw securing brake drum.
4.Remove brake drum.
5.Restrain transfer gearbox drive flange using
LRT-51-003, remove and discard drive flange
nut, remove and discard steel and felt washers.
6.UsingLRT-99-500if necessary, remove drive
flange from transfer gearbox.
7.Remove and discard rear output shaft oil seal
from transfer gearbox.
Refit
8.Clean seal recess.
9.Lubricate new oil seal with transfer gearbox oil.
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41TRANSFER GEARBOX
12
REPAIR
10.Fit new seal usingLRT-41-012.
NOTE: Use end of tool marked’REAR’to
fit seal.
11.Position drive flange, fit new felt and steel
washers.
12.PositionLRT-51-003fit and tighten new drive
flange nut to148 Nm (109 lbf.ft).
13.Position brake drum and tighten screw.
14.Tighten adjuster bolt to25 Nm (18 lbf.ft)then
back off 1 1/2 turns.
15.Check that brake drum is free to rotate.
16.Fit propeller shaft.See PROPELLER SHAFTS,
Repair.
17.Top-up transfer gearbox oil.GASKET - REAR OUTPUT SHAFT HOUSING
Service repair no - 41.20.55
Remove
1.Drain transfer gearbox oil.See
MAINTENANCE ,
2.Remove rear output shaft seal.See this
Section.
3.Mark output shaft housing to main casing for
assembly purposes.
4.Note position of shoulder bolt, remove 6 bolts
securing housing to main casing.
Refit
5.Clean output shaft housing, mating face on main
casing and sealant from bolt threads.
6.Apply Hylosil RTV 102 to mating flange on
output shaft housing.
7.Fit output shaft housing to main casing ensuring
that splines of output shaft are engaged in
differential.
8.Apply Loctite 290 to bolt threads.
9.Fit bolts and tighten by diagonal selection to45
Nm (33 lbf.ft).
10.Fit rear output shaft seal.See this Section.
11.Fill transfer gearbox with oil.See
MAINTENANCE ,
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REAR AXLE AND FINAL DRIVE
1
DESCRIPTION AND OPERATION DESCRIPTION
The welded steel rear 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 rear wheels via the axle shafts and fully
floating hubs which are mounted on tapered roller
bearings.
Lubrication
The differential is lubricated with oil and the hub
bearings with grease.The hub bearings are fitted with inner and outer seals.
The outer seals prevent the differential oil mixing with
the hub grease and the inner seals prevent dirt
ingress into the hub.
Ventilation
Ventilation of the hub bearings is through the outer oil
seals and the differential ventilation pipe, which
terminates at a high level.
Rear axle hub - 90
1.Axle casing
2.Ventilation pipe
3.Axle shaft
4.Wheel studs and hub
5.Wheel bearing stub axle6.Wheel bearings
7.Inner hub seal
8.Outer hub/axle shaft seal
9.Hub lock plate, thrust washer and nuts
10.Brake disc
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51REAR AXLE AND FINAL DRIVE
2
DESCRIPTION AND OPERATION
Rear axle hub - 110/130
1.Axle casing
2.Ventilation pipe
3.Axle shaft
4.Wheel studs and hub
5.Wheel bearing stub axle
6.Wheel bearings
7.Inner hub seal8.Outer hub/axle shaft seal
9.Hub lock plate, thrust washer and nuts
10.Brake disc
11.Drive flange
12.Drive shaft circlip
13.Dust cap
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REAR AXLE AND FINAL DRIVE
3
REPAIR REAR HUB ASSEMBLY - 90
Service repair no - 64.15.01
Remove
1.Place rear axle onto axle stands and remove
road wheel.
2.Release brake hose clips and remove brake
caliper bolts. Secure to one side.
WARNING: Take care not to kink brake
hose.
3.Remove 5 bolts and withdraw axle shaft.
4.Remove joint washer.
5.Bend back lock washer tabs.
6.Remove locknut and lock washer.
7.Remove hub adjusting nut.
8.Remove spacing washer.
9.Remove hub and brake disc assembly complete
with bearings.
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.
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51REAR AXLE AND FINAL DRIVE
4
REPAIR Refit
10.Clean stub axle.
11.Fit hub assembly to stub axle.
12.Fit spacing washer.
13.Fit hub adjusting nut. Tighten to50 Nm (37
lbf/ft).Ensure hub is free to rotate with no
bearing play. Back off adjusting nut 90°and
tighten to10 Nm (7 lbf/ft).
14.Fit a new lock washer.
15.Fit locknut. Tighten to50 Nm (37 lbf/ft).
16.Tab over lock washer to secure adjusting nut
and locknut.
17.Using a new joint washer fit axle shaft to hub.
Tighten bolts to65 Nm (48 lbf/ft).
18.Fit brake caliper. Tighten bolts to82 Nm (61
lbf/ft).Secure brake pipes to axle casing.
19.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)
20.Operate foot brake to locate brake pads before
driving vehicle.
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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.
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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.
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