shaft LAND ROVER DEFENDER 1999 Workshop Manual

41TRANSFER GEARBOX
10
REPAIR Refit
8.Clean oil seal recess.
9.Lubricate new input shaft oil seal with transfer
gearbox oil.
10.Fit oil seal usingLRT-41-012.
NOTE: Use end of tool marked ’FRONT’ to
fit seal.
11.Position drive flange, fit new felt and steel
washers.
12.PositionLRT-51-003fit new drive flange nut and
tighten to148 Nm (109 lbf.ft).
13.Align marks and position front propeller shaft to
output flange. Fit new nuts and tighten to48 Nm
(35 lbf.ft).
14.Fit underbelly panel.See CHASSIS AND
BODY, Repair.
15.Check/top-up transfer gearbox oil.SEAL - REAR OUTPUT SHAFT
Service repair no - 41.20.54
Remove
1.Loosen brake shoe adjuster bolt.
2.Remove rear propeller shaft.See PROPELLER
SHAFTS, Repair.
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TRANSFER GEARBOX
11
REPAIR
3.Remove screw securing brake drum.
4.Remove brake drum.
5.Restrain transfer gearbox drive flange using
LRT-51-003, remove and discard drive flange
nut, remove and discard steel and felt washers.
6.UsingLRT-99-500if necessary, remove drive
flange from transfer gearbox.
7.Remove and discard rear output shaft oil seal
from transfer gearbox.
Refit
8.Clean seal recess.
9.Lubricate new oil seal with transfer gearbox oil.
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41TRANSFER GEARBOX
12
REPAIR
10.Fit new seal usingLRT-41-012.
NOTE: Use end of tool marked’REAR’to
fit seal.
11.Position drive flange, fit new felt and steel
washers.
12.PositionLRT-51-003fit and tighten new drive
flange nut to148 Nm (109 lbf.ft).
13.Position brake drum and tighten screw.
14.Tighten adjuster bolt to25 Nm (18 lbf.ft)then
back off 1 1/2 turns.
15.Check that brake drum is free to rotate.
16.Fit propeller shaft.See PROPELLER SHAFTS,
Repair.
17.Top-up transfer gearbox oil.GASKET - REAR OUTPUT SHAFT HOUSING
Service repair no - 41.20.55
Remove
1.Drain transfer gearbox oil.See
MAINTENANCE ,
2.Remove rear output shaft seal.See this
Section.
3.Mark output shaft housing to main casing for
assembly purposes.
4.Note position of shoulder bolt, remove 6 bolts
securing housing to main casing.
Refit
5.Clean output shaft housing, mating face on main
casing and sealant from bolt threads.
6.Apply Hylosil RTV 102 to mating flange on
output shaft housing.
7.Fit output shaft housing to main casing ensuring
that splines of output shaft are engaged in
differential.
8.Apply Loctite 290 to bolt threads.
9.Fit bolts and tighten by diagonal selection to45
Nm (33 lbf.ft).
10.Fit rear output shaft seal.See this Section.
11.Fill transfer gearbox with oil.See
MAINTENANCE ,
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47 - PROPELLER SHAFTS
CONTENTS
Page
REPAIR
PROPELLER SHAFT - FRONT 1...........................................................................
PROPELLER SHAFT - REAR 1..............................................................................
OVERHAUL
PROPELLER SHAFT - FRONT 1...........................................................................
PROPELLOR SHAFT - REAR 2.............................................................................
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PROPELLER SHAFTS
1
REPAIR PROPELLER SHAFT - FRONT
Service repair no - 47.15.02
Remove
1.Remove underbelly panel.See CHASSIS AND
BODY, Repair.
NOTE: To remove the underbelly panel,
the propeller shaft has to be released from
the front differential flange.
2.Mark propeller shaft to transfer gearbox.
3.Remove 4 nuts securing propeller shaft to
transfer gearbox flange.
4.Remove propeller shaft.
Refit
5.Clean propeller shaft flanges and mating faces.
6.Position propeller shaft to transfer gearbox
flange and tighten nuts to48 Nm (35 lbf.ft).
7.Fit underbelly panel.See CHASSIS AND
BODY, Repair.PROPELLER SHAFT - REAR
Service repair no - 47.15.03
Remove
1.Raise rear of vehicle.
WARNING: Support on safety stands.
2.Using a centre punch, mark relationship of
propeller shaft flanges.
3.Remove 4 nuts securing propeller shaft to park
brake flange.
NOTE: Rotation of propeller shaft may be
required during the above procedure.
4.Remove 4 nuts and bolts securing propeller
shaft to rear axle flange.
NOTE: Rotation of propeller shaft may be
required during the above procedure.
5.Release propeller shaft from park brake.
6.Remove propeller shaft.
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47PROPELLER SHAFTS
2
REPAIR Refit
7.Grease propeller shaft universal joints.
8.Grease propeller shaft spline.
9.Clean propeller shaft flange mating faces.
10.Fit propeller shaft to park brake flange bolts.
NOTE: Ensure relationship marks align.
11.Position propeller shaft to rear axle flange and fit
bolts.
12.Fit nuts and bolts securing propeller shaft to rear
axle flange and tighten to48 Nm (35 lbf.ft).
NOTE: Rotation of propeller shaft may be
required during the above procedure.
13.Fit nuts securing propeller shaft to park brake
and tighten to48 Nm (35 lbf.ft).
NOTE: Rotation of propeller shaft may be
required during the above procedure.
14.Remove stand(s) and lower vehicle.
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PROPELLER SHAFTS
1
OVERHAUL PROPELLER SHAFT - FRONT
Service repair no - 47.15.11
Remove
1.Remove front propeller shaft.See Repair.
2.Thoroughly examine universal joints for signs of
damage or wear.
3.Clean universal joint bearing cups and circlips.
CAUTION: To ensure correct assembly
and reduce possibility of imbalance,
before removing propeller shaft joint mark
position of spider pin relative to journal yoke ears.
4.Remove circlips.
5.Note position and remove grease nipple.
6.Tap yokes to eject bearing cups.
7.Remove bearing cups.
8.Remove spider.
9.Clean yokes and bearing cup locations.Refit
10.Remove bearing cups from new spider.
11.Check all needle rollers are present and
positioned in bearing cups.
12.Enter new spider with seals into yokes of
propeller shaft flange.
13.Partially insert one bearing cup into flange yoke
and enter spider trunnion into bearing cup.
14.Insert opposite bearing cup into flange yoke.
15.Press both cups into place.
16.Press each cup into its respective yoke up to
lower land of circlip groove. Damage may be
caused to cups and seals if cups pass this point.
17.Fit circlips and check no end float exists.
18.Fit grease nipple and lubricate
19.Repeat instructions for opposite end of propeller
shaft as described in 1 to 9.
20.Fit front propeller shaft.See Repair.
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47PROPELLER SHAFTS
2
OVERHAUL PROPELLOR SHAFT - REAR
Service repair no - 47.15.12
Remove
1.Remove rear propeller shaft.See Repair.
2.Thoroughly examine universal joint for signs of
damage or wear.
3.Clean universal joint bearing cups and circlips.
CAUTION: To ensure correct assembly
and reduce possibility of imbalance,
before removing propeller shaft joint mark
position of spider pin relative to journal yoke ears.
4.Remove circlips.
5.Remove grease nipple.
6.Tap yokes to eject bearing cups.
7.Remove bearing cups.
8.Remove spider.
9.Clean yokes and bearing cup locations.Refit
10.Remove bearing cups from new spider.
11.Check all needle rollers are present and
positioned in bearing cups.
12.Enter new spider with seals into yokes of
propeller shaft flange.
13.Partially insert one bearing cup into flange yoke
and enter spider trunnion into bearing cup.
14.Insert opposite bearing cup into flange yoke.
15.Press both cups into place.
16.Press each cup into its respective yoke up to
lower land of circlip groove. Damage may be
caused to cups and seals if cups pass this point.
17.Fit circlips and check no end float exists.
18.Fit grease nipple and lubricate.
19.Repeat instructions for opposite end of propeller
shaft as described in 3 to 9.
20.Fit rear propeller shaft.See Repair.
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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
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51REAR AXLE AND FINAL DRIVE
2
DESCRIPTION AND OPERATION
Rear axle hub - 110/130
1.Axle casing
2.Ventilation pipe
3.Axle shaft
4.Wheel studs and hub
5.Wheel bearing stub axle
6.Wheel bearings
7.Inner hub seal8.Outer hub/axle shaft seal
9.Hub lock plate, thrust washer and nuts
10.Brake disc
11.Drive flange
12.Drive shaft circlip
13.Dust cap
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