1999 LAND ROVER DEFENDER washer

REAR AXLE AND FINAL DRIVE
3
OVERHAUL
25.Withdraw four dished thrust washers.
26.Withdraw lower differential wheel and thrust
washer.
27.Remove differential bearing cones using
LRT-51-500, adaptors 1 and 2 and press
LRT-99-002.
28.Withdraw shim washers fitted between bearing
cones and differential casings.
Remove final drive pinion
29.UsingLTR-51-003to prevent coupling flange
from rotating, remove flange locknut and plain
washer.
30.Support drive pinion and remove coupling flange
by tapping with a hide hammer.
31.Withdraw drive pinion together with inner bearing
cone.
32.Withdraw and discard collapsable bearing
spacer.
33.Withdraw oil seal, gasket and oil thrower.
34.Withdraw outer bearing cone.
35.UsingLRT-51-502, extract pinion inner bearing
cup and shim washers from casing. Note shim
washer thickness.
36.Extract pinion outer bearing cup from casing
usingLRT-51-502.
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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.
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REAR AXLE AND FINAL DRIVE
5
OVERHAUL
55.Position a suitable dial gauge indicator on casing
with stylus registering on back face of crown
wheel.
56.Rotate differential and check total indicated
run-out on crown wheel back face. This must not
exceed 0,05 mm. If run-out is excessive, check
mating faces for dirt and damage; if necessary,
select a new radial position for crown wheel.
When satisfactory, continue with following check.
Differential bearing adjustment
57.Insert two levers between casing and differential
unit at one side.
58.Move differential unit fully to one side of casing;
do not tilt unit.
59.Rotate differential unit to settle bearings,
continue to lever differential to side, then zero
dial gauge indicator.
60.Lever assembly fully to other side of casing,
rotate unit to settle bearings, then note total
indicator reading.
61.Add 0,127 mm, for bearing pre-load, to total
noted in preceding instruction. The sum is then
equal to nominal value of shims required for
differential bearings. Shims are available in
range 0,07 mm, 0,12 mm, 0,25 mm and 0,76
mm. Select total value of shims required.
62.Remove differential unit and bearings and place
aside. Do not fit shim washers until subsequent
’Differential backlash’checks have been made,
instructions 96 to 102.Fit drive pinion
63.Select shim washers of same thickness value as
those removed from under pinion inner cup,
instruction 35, and place ready for fitting.
64.Position outer bearing replacerLRT-51-505,
detail 2, and outer bearing cup on press
LRT-99-502.
65.Locate assembly into pinion housing nose.
66.Place selected shim washers on to inner bearing
cup seating.
67.Position inner bearing cup in casing.
68.Position inner bearing replacerLRT-51-505,
detail 1, ontoLRT-99-502and secure with fixing
nut.
69.Hold still centre screw and turn butterfly lever to
draw in bearing cups.
Note: If above tools are not available, a suitable piece
of tubing, positioned on bearing inner race and a hand
press may be used.
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51REAR AXLE AND FINAL DRIVE
6
OVERHAUL
70.Support inner bearing on bed of hand press and
press drive pinion into bearing.
71.Position pinion and bearing in casing; omit
collapsable spacer at this stage.
72.Fit outer bearing cone onto pinion.
73.Fit coupling flange and plain washer and loosely
fit flange nut.
74.Tighten coupling flange locknut to remove
end-float from pinion.
75.Rotate pinion to settle bearings and slowly
tighten flange locknut. Use a spring balance to
obtain a torque resistance of 11 Kgf/cm (18
lbf/in) to rotate pinion.
Drive pinion markings
76.Check that serial number marked on pinion end
face matches that marked on crown wheel.
77.The markings on end face adjacent to serial
number are of no significance during servicing.
78.The figure marked on end face opposite to serial
number indicates, in thousandths of an inch,
deviation from nominal required to correctly set
pinion. A pinion marked plus (+) must be set
below nominal, a minus (-) pinion must be set
above nominal. An unmarked pinion must be set
at nominal.
79.The nominal setting dimension is represented by
setting gauge blockLRT-54-503, which is
referenced from pinion end face to bottom radius
of differential bearing bore.
Drive pinion adjustment
80.Ensure that pinion end face is free of raised
burrs around etched markings.
81.Remove keep disc from magnetized base of dial
gauge toolLRT-99-006.
82.Place dial gauge and setting gaugeLRT-54-503
on a flat surface and zero dial gauge stylus on to
setting gauge.
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51REAR AXLE AND FINAL DRIVE
8
OVERHAUL 86.Before adjusting shim thickness, check pinion
face marking and if it has a plus (+) figure,
subtract that from shim thickness figure obtained
in previous instruction. Alternatively if pinion has
a minus (-) figure, add amount to shim thickness
figure.
87.Adjust shim thickness under pinion inner cup as
necessary, by amount determined in instructions
85 and 86.
88.Recheck pinion height setting instructions 82 to
84. If setting is correct, mean reading on dial
gauge will agree with figure marked on pinion
end face. For example, with an end face marking
of +3, dial gauge reading should indicate that
pinion is 0.003 in (0.0762 mm) below nominal.
89.When pinion setting is satisfactory, temporarily
remove pinion outer bearing.
90.Fit a new collapsable bearing spacer, flared end
outward, to drive pinion and refit outer bearing.
91.Fit pinion oil seal.
92.Fit oil seal gasket.
93.Fit pinion oil seal, lipped side first, using general
purpose grease or, where available, a
molybdenum disulphide based grease on seal
lip, usingLRT-51-002to drift in seal.
94.Fit coupling flange and plain washer and loosely
fit a new flange nut. SecureLRT-51-003to
coupling flange, using slave fixings.
95.Alternately tighten flange nut and check drive
pinion resistance to rotation until following
figures are achieved, as applicable:
A.Assemblies re-using original pinion bearings:
17,3 to 34,5 kgf cm.
B.Assemblies with new pinion bearings: 34,5 to
46,0 kgf cm.
NOTE: Once the bearing spacer has
started to collapse the torque resistance
build-up is rapid, therefore check
frequently, using a spring balance, to ensure the
correct figures are not exceeded, otherwise a new
collapsable bearing spacer will be required.
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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.
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51REAR AXLE AND FINAL DRIVE
12
OVERHAUL REAR STUB AXLE - 90
Service repair no - 64.15.22.
STUB AXLE COMPONENTS
1.Stub axle to axle casing bolt.
2.Mud shield.
3.Stub axle.
4.Stub axle joint washer.
5.Axle case.Overhaul
1.Remove hub assemblySee Repair. Rear hub
assembly.
2.Remove 6 bolts from stub axle to axle casing.
3.Remove mud shield.
4.Remove stub axle and joint washer.
Renew rear stub axle oil seal
5.Remove and discard oil seal. Lubricate seal and
lip with EP90 oil. Using special toolLRT-51-004
(LST 138)fit new oil seal lip side trailing so that
seal is flush with rear face of stub axle.
Refit
6.Fit new joint washer, stub axle and mud shield
bolts. Tighten bolts to65 Nm (48 lbf/ft).
7.Refit hub assemblySee Repair. Rear Hub
Assembly.
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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.
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