2002 LAND ROVER DISCOVERY wheel

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.
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).

REAR AXLE
OVERHAUL 51-13
22.Align setting gauge LRT-51-018/7 to setting
block, rock gauge to obtain minimum reading. If
reading is lower than required reading,
decrease shim size. If reading is higher than
required reading, increase shim size.
23.Using LRT-51-003 to restrain pinion flange,
remove bolt and washer. Remove pinion
flange.
24.Remove pinion, collect tail bearing and tail
bearing shim.
25.Remove pinion head bearing outer race and
shim. Discard shim. Ensure bearing race
recess is clean and free from burrs.
26.Fit calculated shim, and using LRT-51-018/4 fit
head bearing outer race.
27.Fit pinion, pinion tail bearing and tail bearing
shim.
28.Fit pinion flange and bolt and washer. Using
LRT-51-003 to restrain pinion flange, tighten
bolt to 100 Nm (74 lbf.ft).
29.Rotate pinion in both directions to settle
bearings.
30.Recheck pinion Torque to Turn, adjust if
necessary.
31.Recheck pinion head height.
32.Using LRT-51-003 to restrain pinion flange,
remove bolt and washer. Remove pinion
flange.
33.Discard bolt.34.Using LRT-51-010 fit pinion seal.
35.Ensure spacer and tail bearing are correctly
located.
36.Fit pinion, pinion flange and washer.
37.Fit new pinion flange bolt and tighten to 100 Nm
(74 lbf.ft).
38.Lightly oil differential bearings.
39.Ensure spring dowels are fitted in bearing caps.
40.Fit differential bearing outer races and locate
differential assembly into housing.
41.Fit bearing caps and tighten bolts to 10 Nm (7.5
lbf.ft).
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.

REAR AXLE
51-14 OVERHAUL
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.

FRONT AXLE
REPAIRS 54-5
REPAIRS
Differential - assembly
$% 54.10.01
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove front road wheels.
3.Drain oil from differential.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
4.If same components to be refitted, reference
mark propeller shaft and mating components.
5.Remove 4 nuts and bolts securing propeller
shaft to differential. Release propeller shaft and
tie aside.
6.Remove LH and RH front brake discs.

+ BRAKES, REPAIRS, Brake disc -
front.7.Disconnect each ABS sensor multiplug.
8.Release each harness from brake hose and
hose bracket.

FRONT AXLE
54-6 REPAIRS
9.Remove 4 bolts securing each front wheel hub
to front axle.
10.Release wheel hubs from front axle. Remove
wheel hubs and drive shafts from front axle.
11.Remove oil seal from axle casing.
12.Remove 10 bolts securing differential to axle
casing. Release and remove differential from
axle casing.Refit
1.Clean drive shaft oil seal recess, oil seal
running surface, wheel hub and axle mating
faces.
2.Using a suitable solvent, clean old RTV sealant
from differential and axle mating faces.
3.Apply RTV sealant to differential or axle mating
face.
4.Apply Loctite 243 to threads of differential
securing bolts.
5.Fit differential to axle, fit bolts and tighten to 55
Nm (41 lbf.ft).
6.Position propeller shaft and align reference
marks. Fit bolts and tighten to 47 Nm (35 lbf.ft).
7.Lubricate oil seal lip and running surface with
clean differential oil.
+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
8.Using LRT-54-012 and LRT-99-003, fit new
drive shaft oil seal to axle casing.
9.Apply anti-seize compound to wheel hub and
steering knuckle mating faces.
10.Ensure ABS harnesses are located in cut out in
steering knuckles.
11.Fit drive shafts in axle casing and align wheel
hubs with steering knuckles. 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.

FRONT AXLE
REPAIRS 54-7
13.Fit front brake discs.

+ BRAKES, REPAIRS, Brake disc -
front.
14.Fit front road wheels and tighten nuts to 140
Nm (103 lbf.ft).
15.Remove stand(s) and lower vehicle.
16.Fill differential with oil.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
Seal - differential pinion
$% 54.10.20
Remove
1.Raise front 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 front propeller shaft for
reassembly.
3.Remove 4 nuts and bolts securing propeller
shaft to differential. Release propeller shaft and
tie aside.
4.Using LRT-51-003 to restrain pinion flange,
remove bolt and washer securing pinion flange.
Remove pinion flange.
5.Position container to catch oil spillage.