ECU LAND ROVER DEFENDER 1996 Manual Online

51REAR AXLE AND FINAL DRIVE
2
REPAIRREV: 05/99 Refit
15.Position axle and fit lower links. Tighten fixings
to
176 Nm (130 lbf/ft).
16.If applicable, fit anti-roll bar links to axleSee
REAR SUSPENSION, Repair, Anti-roll bar
links
.
17.Raise axle and locate road springs.
18.Fit coil spring retaining plates and secure with
fixing bolts.
19.Secure pivot bracket ball joint to axle bracket.
Tighten fixing to
176 Nm (130 lbf/ft).
20.Align propeller shaft to differential drive flange
and tighten fixings to
47 Nm (35 lbf/ft).
21.Reconnect flexible brake hose and axle breather
hose.
22.Refit shock absorbers.
23.Fit road wheels and tighten 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)
24.Remove rear chassis support.
25.Bleed brake system
See BRAKES, Repair,
brake system bleed
.

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.

51REAR AXLE AND FINAL DRIVE
4
REPAIRREV: 05/99 Refit
10.Clean stub axle.
11.Fit hub assembly to stub axle.
12.Fit spacing washer.
13.Fit hub adjusting nut. Tighten to
50 Nm (37
lbf/ft).
Ensure hub is free to rotate with no
bearing play. Back off adjusting nut 90°and
tighten to
10 Nm (7 lbf/ft).
14.Fit a new lock washer.
15.Fit locknut. Tighten to
50 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 to
65 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 footbrake to locate brake pads before
driving vehicle.

REAR AXLE AND FINAL DRIVE
5
REPAIR REAR HUB ASSEMBLY - 110/130
Service repair no - 64.15.01
Remove
1.Loosen rear wheel nuts, jack up vehicle and
lower onto axle stands. Remove road wheel.
2.Release brake pipe clips, remove brake caliper
and brake disc shield bolts. Secure to one side.
WARNING: Take care not to kink brake
hose.3.Lever off dust cap.
4.Remove circlip from driveshaft.
5.Remove 5 bolts and withdraw driving member
and joint washer.
6.Bend back lock washer tabs.
7.Remove locknut and lock washer.
8.Remove hub adjusting nut.
9.Remove spacing washer.
10.Remove hub and brake disc assembly complete
with bearings.
Hub components
1.Dust cap.
2.Drive shaft circlip.
3.Drive member.
4.Drive member joint washer.
5.Drive member retaining bolt.
6.Lock nut.
7.Lock washer.
8.Hub adjusting nut.9.Spacing washer.
10.Outer bearing.
11.Hub.
12.Inner bearing.
13.Grease seal.
14.Brake disc
15.Disc retaining bolt.

51REAR AXLE AND FINAL DRIVE
6
REPAIRREV: 05/99 Refit
11.Clean stub axle and drive shaft and fit hub
assembly to axle.
12.Fit spacing washer.
13.Fit hub adjusting nut. Tighten to
50 Nm (37
lbf/ft).
Ensure hub is free to rotate with no
bearing play.
14.Back off adjusting nut 90°and tighten to
10 Nm
(7 lbf/ft).
15.Fit a new lock washer.
16.Fit locknut. Tighten to
50 Nm (37 lbf/ft).
17.Tab over lock washer to secure adjusting nut
and locknut.
18.Fit a new joint washer to driving member and fit
member to hub. Tighten bolts to
65 Nm (48
lbf/ft).
19.Fit circlip and dust cap.
20.Fit brake disc shield and brake caliper. Tighten
bolts to
82 Nm (61 lbf/ft).
21.Bleed brake systemSee BRAKES, Repair,
Brake system bleed
.
22.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)
23.Operate footbrake to locate brake pads before
driving vehicle.

REAR AXLE AND FINAL DRIVE
7
REPAIR DIFFERENTIAL ASSEMBLY - 90
Service repair no - 51.15.01
Remove
1.Using suitable container, drain axle oil.
2.Mark differential and propeller shaft flanges to
facilitate reassembly.
3.Remove 4 bolts and disconnect propeller shaft
from differential. Tie aside.
4.Remove 5 hub drive member bolts and withdraw
axle half shafts sufficiently to disengage from
differential unit.
5.Remove 10 nuts securing differential to axle
case.
6.Withdraw differential unit.
NOTE: The differential unit can only be
serviced as a complete assembly with
matching drive pinion. For advice ring
Land Rover Service Department.Refit
7.Ensure mating faces are clean and apply a bead
of RTV sealant to axle case.
8.Support differential unit and position on axle
casing.
9.Secure with self locking nuts and tighten to
40
Nm (30lbf/ft).
10.Align marks on flanges and secure propeller
shaft to differential. Tighten bolts to
48 Nm (35
lbf/ft).
11.Refit half shafts, using new drive member
gaskets. Tighten bolts to
65 Nm (48 lbf/ft).
12.Refill axle oil with approved lubricantSee
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
.

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 to
95 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.

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.

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 slinger.
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.

FRONT AXLE AND FINAL DRIVE
1
REPAIR REV: 05/99 FRONT AXLE ASSEMBLY
Service repair no - 54.10.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
axle when lowering or repositioning axle.
1.Support chassis front.
2.Remove road wheels.
3.Support axle weight with hydraulic jack.
4.Remove radius arms to chassis frame nuts.
5.Disconnect steering damper from track rod.
Using a extractor remove track rod links from
swivel pin arms.
6.Remove four nuts and bolts securing radius
arms to axle bracket.
7.Remove radius arms.
8.Remove bolts securing brake hose brackets .
Refit bolts to prevent oil leakage.
9.Remove bolts from brake calipers and tie to one
side.
10.Remove nuts and washers securing shock
absorbers to axle.
11.Disconnect drag link from swivel pin housing
arm.
12.Remove two nuts and bolts securing panhard
rod to axle bracket. Lift rod clear of axle.
13.Mark for reassembly drive shaft flanges.
Remove four nuts and bolts, tie propeller shaft to
one side.
14.Release axle ventilation pipe banjo and lower
axle assembly. Remove road springs.
15.Disconnect anti-roll bar link
See FRONT
SUSPENSION, Repair, Anti-roll bar ball
.
16.Remove axle assembly.
Refit
17.Position axle under vehicle, supporting left side
of axle, and fit anti-roll bar links
See FRONT
SUSPENSION, Repair, Anti-roll bar links
.
18.Fit propeller shaft. Tighten bolts to
47 Nm (35
lbf/ft).
19.Fit panhard rod to axle bracket. Tighten bolts to
88 Nm (65 lbf/ft).
20.Fit drag link to swivel pin arm. Tighten fixings to
40 Nm (30 lbf/ft).
21.Fit shock absorbers to axle.
22.Fit brake calipers. Tighten bolts to
82 Nm (60
lbf/ft).
23.Tighten upper swivel pin bolts to78 Nm (58
lbf/ft).
24.Fit radius arms to axle brackets. Tighten bolts to
197 Nm (145 lbf/ft).
25.Fit steering damper to track rod.
26.Fit radius arms to chassis side member. Tighten
fixings to
197 Nm (145 lbf/ft).
27.Tighten track rod end to40 Nm (30 lbf/ft)and fit
new split pin.
28.Remove chassis supports, fit road wheels and
tighten 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)