1999 LAND ROVER DISCOVERY wheel

REAR AXLE
REPAIRS 51-5
REPAIRS
Differential - assembly
$% 51.15.01
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Drain oil from differential.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
3.If same components are to be refitted,
reference mark propeller shaft and mating
components.
4.Remove 3 nuts and bolts securing flexible
coupling to pinion flange. Release propeller
shaft and tie aside.
5.Using tool LRT-51-008, extract the centralising
peg from the pinion flange. Remove the
centralising peg from the tool.6.Remove LH and RH rear brake discs.

+ BRAKES, REPAIRS, Brake disc -
rear.
7.Disconnect each ABS sensor multiplug.
8.Release each harness from brake hose and
hose bracket.
9.Remove 4 bolts securing each rear wheel hub
to rear axle.
M51 0041B
5
4
M51 0056
LRT-51-008

REAR AXLE
51-6 REPAIRS
10.Release and remove wheel hubs and drive
shafts from rear axle. Remove and discard 'O'
rings from wheel hubs.
11.Remove 10 bolts securing differential to axle.
Release and remove differential from axle. Refit
1.Clean drive shafts, wheel hubs and wheel hub
locations in rear axle.
2.Using a suitable solvent, remove all traces
sealant from differential and axle mating faces.
3.Apply sealant, Part No. STC 3811 to differential
or axle mating face.
4.Apply sealant, Part No. STC 50552 to threads
of differential securing bolts.
5.Fit differential to axle, fit bolts and tighten to 55
Nm (41 lbf.ft).
6.Clean pinion flange and centralising peg.
7.Using a tubular drift, fit centralising peg to
pinion flange. Ensure that the large diameter
part of the centralising peg is below pinion
flange mounting surface.
8.Position propeller shaft and align reference
marks.
9.Fit nuts and bolts securing flexible coupling to
pinion flange and tighten to 76 Nm (56 lbf.ft)
10.Lubricate 2 new wheel hub 'O' rings with clean
differential oil.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication. Install 'O' rings on wheel hubs.
11.Fit LH and RH drive shafts and wheel hubs to
rear axle. Fit wheel hub bolts and tighten to 100
Nm (74 lbf.ft).
12.Connect each ABS sensor multiplug and
secure harness to harness bracket and brake
hose.
13.Fit LH and RH rear brake discs.

+ BRAKES, REPAIRS, Brake disc -
rear.
14.Remove stand(s) and lower vehicle.
15.Fill differential with oil.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
M51 0042B

REAR AXLE
OVERHAUL 51-9
OVERHAUL
Differential assembly
$% 51.15.07
Disassembly
1.Remove differential assembly.
2.Secure differential assembly in a vice or stand.
3.Remove roll pins securing adjusting nuts, using
LRT 51-018-5 loosen adjusting nuts.
4.Reference mark bearing caps to aid assembly.
5.Remove bolts securing bearing caps and
remove caps.6.Remove crown wheel assembly and collect
bearing outer races.
7.Mark outer races to bearings to aid assembly.
8.Using LRT-51-003 to restrain pinion flange
remove bolt and collect washer.

REAR AXLE
OVERHAUL 51-11
16.Using a two legged puller and LRT 51-018/6,
remove the differential bearings.
17.Secure the crown wheel assembly in a vice.
18.Remove and discard 10 bolts securing the
crown wheel to carrier.
19.Carefully remove the crown wheel from the
carrier.20.Remove and discard roll pin securing carrier
cross shaft and remove cross shaft.
21.Rotate gears to the open part of carrier and
remove planet gears.
22.Remove sun gears.

REAR AXLE
51-12 OVERHAUL
Inspect
1.Clean and inspect all components for wear and
damage.
2.Fit planet gears and rotate to align cross shaft
holes.
3.Fit cross shaft, ensure roll pin hole is aligned.
4.Secure cross shaft with new roll pin.
5.Fit crown wheel to carrier, fit new bolts and
tighten to 60 Nm (44 lbf.ft).
6.Ensure original head bearing shim is clean and
free from burrs and fit under bearing race.
7.Ensure pinion bearing cup recesses are clean
and free of burrs and using LRT-51-018-4 fit
pinion head and tail bearing races.
8.Fit pinion head bearing to pinion.
9.Lubricate bearings with thin oil.
10.Ensure original tail bearing shim is clean and
free from burrs and fit under bearing race.
11.Fit pinion and pinion tail bearing.
12.Fit pinion flange, washer and bolt.
13.Use LRT-51-003 to restrain pinion flange.
14.Tighten pinion flange bolt to 100 Nm (74 lbf.ft).
15.Check pinion for end float. Should read zero.16.Rotate pinion several times to settle bearings,
check pinion Torque to Turn. Torque to Turn
should be recorded during pinion rotation.
Pinion Torque to Turn should be 4 to 6 Nm (3 to
4.5 lbf.ft).
17.Adjust size of tail bearing shim to obtain correct
pinion Torque to Turn (0.025 mm = 1 Nm
(0.001' = 0.7 lbf.ft) approximately).
18.Position LRT-51-018-7 on surface plate,
establish zero and reference DTI.
19.Ensure pinion height setting block, setting
gauge and mating faces are clean and free
from burrs.
20.Locate setting block LRT-51-018/11 over
pinion head, ensure it is fully seated in position.

REAR AXLE
51-14 OVERHAUL
42.Fit adjusting nuts, tighten crown wheel side nut
to 22 Nm (16 lbf.ft). Ensure opposing nut is
loose.
43.Position DTI to check crown wheel backlash.
Adjust opposing nut to obtain correct crown
wheel backlash.
44.Rotate pinion in both directions to settle
bearings.
45.Measure in 3 places to obtain correct crown
wheel backlash.
NOTE: Crown wheel backlash should be within
0.076 mm - 0.177 mm (0.003' - 0.007').
46.Align adjusting nuts to next roll pin slot, do not
loosen nuts to align slots.
47.Tighten bearing cap bolts to 90 Nm (66.5 lbf.ft).
48.Secure adjusting nuts with new roll pins.
49.Apply Prussian Blue to crown wheel teeth to
check tooth contact.50.Rotate pinion several times to obtain full tooth
contact.
51.A = Normal pattern, the drive pattern should be
centred on the gear teeth. The coast pattern
should be centred on the gear teeth but may be
towards the toe. There should be some
clearance between the pattern and the top of
the gear teeth.
52.B = Backlash correct, thinner pinion shim
required.
53.C = Backlash correct, thicker pinion shim
required.
54.D = Pinion shim correct, decrease backlash.
55.E = Pinion shim correct, increase backlash.
56.Note assembly Torque to Turn when checking
tooth contact. Total Torque to Turn should not
exceed 10.85 Nm (8 lbf.ft).
Reassembly
1.Fit differential assembly.

FRONT AXLE
54-2 DESCRIPTION AND OPERATION
Description
General
The front axle consists of an axle casing with a differential unit attached to the right of the vehicle centre line. A wheel
hub is installed in a steering knuckle at each end of the axle casing and connected to the differential unit by a drive
shaft.
Axle casing
The axle casing is of welded construction, with brackets on the casing exterior for attachment to the front suspension.
Yokes at each end of the casing incorporate upper and lower ball joints for attachment of the steering knuckles.
A differential cover on the front of the axle casing contains an oil level plug for checking and replenishment of the
differential lubricating oil. A magnetic drain plug is installed on the underside of the casing. An oil seal is installed in
each end of the axle casing to prevent leakage past the drive shafts.
The interior of the axle casing is ventilated through a breather tube inserted in a red plastic sleeve in the top of the
casing. The open end of the breather tube is located in the left rear corner of the engine compartment.
Differential unit
The differential unit is of the spiral bevel type, lubricated by splash oil. The unit consists of a differential carrier
attached to a pinion housing. In the pinion housing, the pinion is splined to a drive flange which is secured with a bolt
and washer. An oil seal prevents leakage past the drive flange.
Steering knuckle
The steering knuckles are mounted on upper and lower ball joints in the yokes at the end of the axle casing. A tension
collet, in the lower mounting point of each steering knuckle, accommodates manufacturing tolerances to enable the
correct tightening of both ball joints. Lugs are incorporated on the steering knuckles for attachment of the steering
system drag link and track rod.

FRONT AXLE
DESCRIPTION AND OPERATION 54-3
Wheel hub
Section through wheel hub
1Drive shaft
2Axle casing
3Gaiter
4Upper ball joint
5Constant velocity joint
6Steering knuckle
7Hub bearing
8Hub flange9Wheel stud
10Stake nut
11ABS sensor ring
12Tension collet
13Lower ball joint
14Securing bands
15Shield
16Oil seal
Each wheel hub consists of a hub flange pressed into a hub bearing.
The hub flange is splined to accept the constant velocity joint of the drive shaft, which is secured to the hub flange
with a stake nut. Five studs are installed in the hub flange for the wheel nuts and a threaded hole is provided for the
brake disc securing screw.
The outer race of the hub bearing is bolted to the steering knuckle. The hub bearing is a sealed unit which contains
twin opposed roller bearings, pre-packed with grease during manufacture. A toothed ABS sensor ring is integrated
into the inner race of the hub bearing. An opening in the outer race of the hub bearing accommodates the ABS sensor.
Drive shaft
Each drive shaft consists of a solid rod, splined at both ends, with a constant velocity joint installed on the outboard
end. A shield is incorporated onto each rod to protect the oil seals in the axle casing. The constant velocity joint is of
the ball and socket type. A shaft on the constant velocity joint is splined to the hub flange. The constant velocity joint
is pre-packed with grease and protected by a gaiter. Two securing bands retain the gaiter in position.