1999 LAND ROVER DISCOVERY ECU

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
REPAIRS 51-7
Seal - differential pinion
$% 51.20.01
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.Reference mark rear propeller shaft for
reassembly.
3.Remove 3 nuts and bolts securing flexible
coupling to pinion flange. Tie propeller shaft
aside.
4.Using tool LRT-51-008, extract the centralising
peg from the pinion flange. Remove the
centralising peg from the tool.5.Using tool LRT-51-003 to restrain pinion
flange, remove bolt and washer securing pinion
flange. Remove pinion flange.
6.Position container to catch oil spillage
7.Using a suitable lever, remove pinion oil seal.
Take care to avoid damage to oil seal
recess.
M51 0043A
2
3
M51 0056
LRT-51-008
M51 0047A
LRT-51-003

REAR AXLE
51-8 REPAIRS
Refit
1.Clean pinion oil seal recess and pinion flange.
2.Lubricate oil seal lip with clean differential oil.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Using tool LRT-51-010, fit pinion oil seal.
4.Fit pinion flange and securing bolt and washer.
Using tool LRT-51-003 to restrain pinion
flange, tighten pinion flange securing bolt to
100 Nm (74 lbf.ft).
5.Using a tubular drift, fit centralising peg to
pinion flange. Ensure that large diameter part of
centralising peg is below pinion flange
mounting surface.
6.Position propeller shaft and align reference
marks.
7.Fit nuts and bolts securing flexible coupling to
pinion flange and tighten to 76 Nm (55 lbf.ft).
8.Remove stand(s) and lower vehicle.
9.Check differential oil level.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
M51 0047A
LRT-51-003

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.