differential LAND ROVER DEFENDER 1996 User Guide

41TRANSFER GEARBOX
4
REPAIR
36.Remove retaining nut, release clamp, and
disconnect speedometer cable from transfer
gearbox.
37.Remove battery earth strap retaining nut, 1 nut
and 4 bolts, securing transfer box to main
gearbox extension case.
38.Remove retaining nut securing earth leads to RH
side of transfer box.
39.Fit three guide studs,LRT-41-009, through
transfer box bolt holes to support it during
removal.
40.Lower hoist and withdraw transfer box from main
gearbox.
41.Remove transfer box.Refit
42.Ensure joint faces of transfer box and main
gearbox are clean and guide studs,LRT-41-009,
are fitted to extension case.
43.Lubricate oil seal in joint face of transfer box.
44.Secure transfer box to adaptor plate on lifting
hoist and raise hoist until transfer box can be
located over guide studs.
45.Remove guide studs, fit battery earth strap, and
secure transfer box to main gearbox extension
case. Tighten fixings to
45 Nm (33 lbf/ft).
46.Fit electrical leads to differential lock switch.
47.Raise hoist and remove wooden block
supporting main gearbox.
48.Secure LH and RH mounting brackets to
gearbox and tighten fixings to
55 Nm (41 lbf/ft).
49.With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable fitment of crossmember.
50.Position chassis crossmember and locate over
fixing studs of LH and RH gearbox mounting
rubbers .
51.Align crossmember and secure to chassis with 4
nuts and bolts on each side.
NOTE: Fit battery earth strap retaining clip
to LH top bolt.
52.Remove body jack.
53.Fit retaining nut to LH and RH mounting rubbers.
Tighten to
21 Nm (15 lbf/ft).
54.Remove 4 bolts securing hoist adaptor plate to
transfer box bottom cover.
55.Lower hoist and move aside.
56.Clean threads of the 4 bolts, coat with Loctite
290, and fit to transfer box bottom cover. Tighten
to
25 Nm (18 lbf/ft).
57.Fit earth leads to RH side of transfer box.
58.Connect differential lock control operating rod to
pivot arm.
59.Fit speedometer cable to transfer box.
60.Fit front and rear propeller shafts to transfer box.
Tighten nuts to
47 Nm (33 lbf/ft).
61.Fit intermediate silencer.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
silencer - 90; Refit
orSee MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
pipe - 110/130; Refit
.
62.Refill transfer box with recommended oil
See
SECTION 10, Maintenance, Under vehicle
maintenance

TRANSFER GEARBOX
1
SPECIFICATIONS, TORQUE REV: 05/99 TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Transfer gearbox
Pinch bolt - operating arm to crank arm 9......................................................
End cover gear change housing 9.................................................................
Bottom cover to transfer case 25....................................................................
Front output housing to transfer case 25........................................................
Cross shaft housing to front output housing 25...............................................
Gear change housing 25.................................................................................
Pivot shaft to link arm 25.................................................................................
Connecting rod to adjustable clevis 25...........................................................
Anti-rotation plate intermediate shaft 25.........................................................
Front output housing cover 25........................................................................
Pivot bracket to extension housing 25............................................................
Finger housing to front output housing 25......................................................
Bearing housing to transfer case 25...............................................................
Brake drum to coupling flange 25...................................................................
Bearing housing cover to transfer gearbox 45................................................
Rear output speedometer housing to transfer gearbox 45..............................
Selector finger to cross shaft high/low 25.......................................................
Selector fork, high/low to shaft 25...................................................................
Transmission brake to speedometer housing 72............................................
Gate plate to grommet plate 9.......................................................................
Gearbox to transfer case 45...........................................................................
Oil drain plug 30..............................................................................................
Oil filler/level plug 30.......................................................................................
Differential case (front to rear) 60...................................................................
Output flanges 162...........................................................................................
Differential case rear stake nut 72..................................................................
Transfer breather 15.......................................................................................
Transfer box front drive flange to drive shaft 45..............................................
Transfer box rear drive flange to drive shaft 45..............................................
Transfer gearbox mounting brackets to chassis 30........................................
Mounting brackets to transfer gearbox 55......................................................
Mounting rubbers to mounting brackets 21.....................................................

REAR AXLE AND FINAL DRIVE
1
DESCRIPTION AND OPERATION DESCRIPTION
The welded steel rear axle casing houses a separate
spiral bevel type differential unit, which is off set to the
right of the vehicle centre line. The differential unit
drives the rear wheels via the axle shafts and fully
floating hubs which are mounted on tapered roller
bearings.
Lubrication
The differential is lubricated with oil and the hub
bearings with grease.The hub bearings are fitted with inner and outer seals.
The outer seals prevent the differential oil mixing with
the hub grease and the inner seals prevent dirt
ingress into the hub.
Ventilation
Ventilation of the hub bearings is through the outer oil
seals and the differential ventilation pipe, which
terminates at a high level.
Rear axle hub - 90
1.Axle casing
2.Ventilation pipe
3.Axle shaft
4.Wheel studs and hub
5.Wheel bearing stub axle6.Wheel bearings
7.Inner hub seal
8.Outer hub/axle shaft seal
9.Hub lock plate, thrust washer and nuts
10.Brake disc

REAR AXLE AND FINAL DRIVE
1
FAULT DIAGNOSIS FAULT DIAGNOSIS
Complaint - Oil leaks
An external leak of lubrication from the hub seals can
be caused by a faulty internal seal. For example, if the
seals which separate the differential from the hubs are
faulty and the vehicle is operating or parked on an
embankment, oil from the differential may flood one
hub resulting in a lack of lubrication in the differential.
When a seal is found to be leaking check the axle
ventilation system, as a blockage can cause internal
pressure to force oil past the seals.
See 'Description and Operation' for illustrations of oil
seal locations.
When investigating hub seal leaks check the grease
for dilution with oil. Also check the differential oil level,
for signs of metal particles in the oil and the condition
of internal seals.
If the vehicle is driven in deep water with defective oil
seals, water may contaminate the lubricants and raise
the differential oil level, giving a false impression that
the housing has been overfilled.
Do not assume that a high oil level in the
differential is due to over filling or, that a low level
is because of an external leak.

REAR AXLE AND FINAL DRIVE
1
REPAIR REAR AXLE
Service repair no - 51.25.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
the axle when lowering or repositioning
axle.
1.Drain brake system.
2.Support chassis rear.
3.Remove road wheels.
4.Support axle weight with hydraulic jack.
5.Disconnect shock absorbers.
6.Disconnect flexible brake hose at RH chassis
side member and breather hose at banjo
connection on axle casing.
7.Disconnect lower links at axle.8.Mark differential and propeller shaft flanges with
identification marks for assembly.
9.Remove 4 nuts and bolts, lower propeller shaft
and tie to one side.
10.Disconnect pivot bracket ball joint at axle
bracket.
11.Release bolts and remove coil spring retaining
plates.
12.Lower axle and remove road springs.
13.If applicable, remove anti-roll bar links at axle
See REAR SUSPENSION, Repair, anti-roll
bar
.
14.Remove axle assembly.

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
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
.

REAR AXLE AND FINAL DRIVE
1
OVERHAUL DIFFERENTIAL ASSEMBLY - 110/130
Service repair no - 51.15.07
Overhaul
1.Drain off differential lubricating oil, and refit plug.
2.Remove rear axle assembly from vehicle
See
Repair, Rear axle
3.Remove hub driving member fixings.
4.Withdraw driving member and axle shaft
sufficiently to disengage differential.
5.Repeat instruction 4 for other axle shaft.
6.Remove fixings and support strip at differential
cover and withdraw cover and joint washer.
7.Note relationship marking on bearing caps and
axle casing to ensure correct refitting.
8.Remove fixings and withdraw differential bearing
caps.
9.Clean out and examine spreader tool pegholes
provided in gear casing face; ensure that holes
are free from dirt and burrs and damage.
10.Ensure that turnbuckle adjuster is free to turn.
Using axle spreader 18G31C
11.Fit axle spreader to engage peg holes.
(Spreader18G131C, Adaptor pegs18G131F)
12.Using a spanner, turn adjuster until all free play
between spreader and casing is taken up,
denoted by adjuster becoming stiff to turn.
13.Check that side members of spreader are clear
of casing.
14.Stretch casing, rotating adjuster by one flat at a
time, until differential assembly can be levered
out. Do not lever against spreader; use suitable
packing under levers to avoid damage to casing.

51REAR AXLE AND FINAL DRIVE
2
OVERHAUL
CAUTION: To prevent permanent damage
to the gear carrier case, it must not be
over-stretched. Each flat on the turnbuckle
is numbered to enable a check to be made on the
amount turned. The maximum stretch permitted is
0,30 mm, equivalent to three flats.
15.Ease off adjuster and remove spreader.
Using axle compressor LRT-51-503 (GKN 131)
16.Place tool on to differential casing, as illustrated,
with weld seam uppermost. Ensure that plates
rest squarely on differential machined surface
and end bars butt against edges of casing.
17.Tighten adjusting nuts by hand only, until all
slack is taken up.
18.Continue to tighten both nuts alternately with a
spanner, one flat at a time, to a maximum of
three flats.
19.Carefully lever-out differential assembly.
Dismantle differential
20.Add alignment marks between crown wheel and
differential case for reassembly purposes, then
remove fixings and withdraw crown wheel.
21.Note alignment markings on two differential
casings to ensure correct refitting, then remove
fixings.
22.Lift off upper case.
23.Withdraw upper differential wheel and thrust
washer.
24.Lift out cross-shaft and pinions.

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 toger 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.