service LAND ROVER DISCOVERY 1995 Workshop Manual

47PROPELLER SHAFTS
4
REPAIR REAR PROPELLER SHAFT
Service repair no - 47.15.03
NOTE: SGF rubber coupling should be left
attached to propeller shaft. Only remove
coupling from propeller shaft if
replacement is required.
Remove
1.Scribe alignment marks on flanges at both ends
of propeller shaft to ensure correct refitting.
2.Remove three nuts and bolts securing flexible
coupling to axle flange.
3.Remove nuts securing propeller shaft flange to
transfer gearbox.
4.Raise propeller shaft at gearbox end detach
coupling from spigot at differential and withdraw
shaft.
NOTE: For replacement of spigot (pinion
flange centralising peg).
See REAR AXLE
AND FINAL DRIVE, Overhaul, Axle
Differential Assembly
Overhaul
Service repair no - 47.15.12
NOTE: Refer to front propeller shaft
overhaul procedure for gearbox end of
shaft. The SGF rubber coupling is a
non-serviceable item.
Refit
5.Locate flexible coupling over spigot, align
scribed marks and secure at transfer gearbox.
Tighten to
47 Nm.
6.Secure flexible coupling to axle flange with three
nuts and bolts and Tighten to
78 Nm.
FLEXIBLE COUPLING
NOTE: Flexible coupling should only be
removed if a new coupling is to be fitted.
Remove
1.Remove rear propeller shaft.
See Rear
Propeller Shaft.
2.Remove nuts and bolts securing flexible
coupling to propeller shaft.
Refit
3.Reverse removal procedure. Fit nuts and bolts.
Tighten to
78 Nm.

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 ABS wiring harness multi-plug at
jump hose bracket, if applicable.
6.Disconnect shock absorbers.
7.Disconnect flexible brake hose at connection
under floor.
8.Disconnect lower links at axle.
9.Mark differential and propeller shaft flanges with
identification marks for assembly. Remove four
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.Disconnect anti-roll[sway] bar links to axle.
See
REAR SUSPENSION, Repair, Anti-Roll[Sway]
Bar Ball Joint Links
14.Remove axle assembly.
Refit
15.Position axle and fit lower links. Tighten to
176
Nm
16.Reverse removal procedure.
17.Tighten pivot bracket ball joint to axle to
176 Nm.
18.Tighten propeller shaft to differential drive flange
to
47 Nm
19.Bleed brake system.See BRAKES, Repair,
Brake System Bleed

51REAR AXLE AND FINAL DRIVE
2
REPAIR REAR BRAKE DISC NON ABS
Service repair no - 70.10.11.
Remove
1.Remove rear hub assembly.
See Rear Hub
Assembly
2.Remove disc bolts.
3.Remove disc from rear hub.
Refit
4.Fit disc to rear hub.
5.Fit disc bolts. Tighten to
73 Nm.
6.Check total disc run out, this must not exceed
0,15 mm. If necessary reposition disc.
7.Fit rear hub assembly.See Rear Hub
Assembly
Disc reclamation
8.Check disc thickness. This dimension may be
reduced to minimum thickness of 12 mm.
Machine equal amounts off each face.REAR BRAKE DISCS ABS
Service repair no - 70.11.11.
Remove
1.Remove rear hub assembly.
See Rear Hub
Assembly
2.Remove five nyloc nuts.
3.Remove sensor ring.
4.Remove five hub to disc retaining bolts.
5.Remove disc from hub.
Refit
6.Fit disc onto hub.
7.Apply loctite 270 and fit hub to disc retaining
bolts. Tighten to
73 Nm.
8.Using new nyloc nuts fit sensor ring.
9.Check total disc run out, this must not exceed
0,15 mm. If necessary reposition disc.
10.Fit hub assembly.
See Rear Hub Assembly
Disc reclamation
11.Check disc thickness. This dimension may be
reduced to a minimum thickness of 12 mm.
Machine equal amounts off each face.

REAR AXLE AND FINAL DRIVE
3
REPAIR REAR HUB ASSEMBLY
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 five 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
1. Sensor ring retaining nut ABS.
2. Axle shaft.
3. Axle shaft joint washer.
4. Axle shaft retaining bolt (five off).
5. Lock nut.
6. Lock washer.
7. Hub adjusting nut.
8. Spacing washer.
9. Outer bearing.
10. Hub.
11. Inner bearing.
12. Grease seal.
13. Brake disc.
14. Disc retaining bolt (five off).
15. Sensor ring ABS.

REAR AXLE AND FINAL DRIVE
1
OVERHAUL AXLE DIFFERENTIAL ASSEMBLY
Service repair no - 51.15.07.
DISMANTLE
NOTE: Mark differential components so
their original positions relative to other
components is maintained. Bearing caps
must not be interchanged.
1.Remove axle shafts then differential assembly
fom axle.
2.Remove roll pin securing bearing nut locking
fingers to bearing caps. Remove locking fingers.
3.Loosen bearing cap bolts and mark caps for
assembly.
4.Using service tool LRT-54-508, remove bearing
adjusting nuts.
5.Remove bearing cap bolts and bearing caps.
6.Remove crown wheel differential unit and
bearings.
Remove pinion FRONT AXLE DIFFERENTIAL
ONLY
7.Remove pinion flange nut using service tool
LRT-51-003 to restrain flange.
8.Remove washer and pinion drive flange.
9.Remove pinion complete with bearing and outer
bearing shims.
10.Remove pinion flange oil seal, spacer and
bearing.
Remove pinion REAR AXLE DIFFERENTIAL ONLY
7.Remove pinion flange centralizing peg using
service tool LRT-51-008.
8.Remove pinion flange nut using service tool
LRT-51-003 to restrain flange.
9.Remove pinion complete with bearing and outer
bearing shims.
10.Remove pinion flange oil seal and bearing.
11.Using service tool LRT-54-505, remove pinion
head bearing track and shim and drive out outer
bearing of differential housing.

51REAR AXLE AND FINAL DRIVE
2
OVERHAUL
12.Remove pinion head bearing with service tool
LRT-99-002.
13.Remove bolts and washers securing crown
wheel to differential flange. Remove crown
wheel.
14.Remove differential carrier bearings.
15.Remove circlips and extract differential cross
shaft.
16.Withdraw differential gears and pinions.
17.Clean all components.
INSPECTION
18.Check all bearings for wear and pitting.
19.Check all gears for wear, scuffing, pitting and
damaged teeth.
20.Supplied as matched sets are: crown wheel and
pinion, pinion housing and bearing caps.
ASSEMBLE
Differential gears
21.Fit differential gears to differential housing.
22.Fit differential cross shaft and circlips.

REAR AXLE AND FINAL DRIVE
3
OVERHAUL 23.Check gear for freedom of rotation and backlash.
Nominal backlash should be present. Excess
backlash necessitates replacement of gears or
differential housing.
24.Check serial number marked on pinion end face
matches that on crown wheel.
25.Clean and fit crown wheel.
26.Fit carrier bearings and assemble tracks to
bearings.
27.Place differential housing with crown wheel and
bearings in pinion housing.
28.Fit bearing caps and bolts. Do not tighten bolts.
29.Fit bearing adjusting nuts and adjust to obtain
zero end float.
30.Tighten bearing cap bolts to90 Nm.
31.Check crown wheel for run-out. This should not
exceed 0,10 mm. If exceeded examine crown
wheel and mounting flange for burrs, grit, etc.
Refit and recheck. A buckled or damaged
differential housing flange is corrected by
replacing differential gear housing.
32.After checking run out remove differential
housing from pinion housing.
33.Remove crown wheel bolts and refit using
Loctite 'Studlock'. Tighten to
58 Nm.
34.Fit pinion head bearing track and original shim to
pinion housing. Use service tools LRT-54-505
and LRT-54-506. If fitting a new shim use
minimum 1.27 mm thickness.

51REAR AXLE AND FINAL DRIVE
4
OVERHAUL 35.Fit pinion outer bearing track to pinion housing.
Use service tools LRT-54-505 and LRT-54-507.
36.Fit pinion head bearing to pinion. Use service
tool LRT-54-502.
37.Fit pinion into its location without shims for
bearing pre-load.
38.Fit outer bearing, and spacer (front axle
differential only).
39.Fit driving flange, washer and nut.
40.Do not fit oil seal at this stage.
41.Tighten pinion flange nut until force required to
rotate pinion is
3Nmif new bearings are fitted.
This will pre-load bearings to check pinion height
dimension.
NOTE: If using original bearings, pre-load
figure is 1.5 Nm.
Drive pinion markings
NOTE: Markings on end face adjacent to
serial number are of no relevance to
servicing.
42.Figures marked on end face opposite to serial
number show in thousandths of an inch,
deviation from nominal, required to set pinion.
Pinions marked plus (+) must be set below
nominal. Pinions marked minus (-) must be set
above nominal. Unmarked pinions must be set at
nominal.

51REAR AXLE AND FINAL DRIVE
8
OVERHAUL CROWN WHEEL/PINION BACKLASH
ADJUSTMENT
63.Place differential housing in pinion housing.
64.Fit bearing caps and partly tighten bolts.
65.Fit bearing adjusting nuts.
66.Mesh crown wheel to pinion. Using service tool
LRT-54-508 loosen left bearing adjuster nut.
67.Tighten right nut until crown wheel/pinion
backlash is just removed.68.Tighten left nut until it contacts bearing. Continue
turning until a backlash of 0,10 to 0,17 mm is
met.DO NOTloosen right nut otherwise bearing
preload will be affected.
69.Fit locking fingers and roll pins. Align locking
finger with a slot.
70.Evenly tighten bearing cap bolts to
90 Nm.
71.Recheck crown wheel/pinion backlash.
72.Lubricate bearings and gears.

REAR AXLE AND FINAL DRIVE
9
OVERHAUL REAR HUB ASSEMBLY
Service repair no - 61.15.13.
Overhaul
1.Remove rear hub assembly.
See Repair, Rear
Hub Assembly
2.Remove outer bearing.
3.Remove five nyloc nuts and withdraw ABS
sensor ring, if applicable.
4.Mark, for reassembly, position of hub to brake
disc.5.Remove five bolts and separate hub from brake
disc.
WARNING: A maximum of two road wheel
retaining studs can be renewed. Should
more studs be unserviceable fit new hub
with studs.
6.Remove grease seal and inner bearing from
hub.
7.Remove inner and outer bearing tracks.
REAR HUB COMPONENTS
1. Sensor ring retaining nut ABS.
2. Axle shaft.
3. Axle shaft joint washer.
4. Axle shaft retaining bolt (five off).
5. Lock nut.
6. Lock washer.
7. Hub adjusting nut.
8. Spacing washer.9. Outer bearing.
10. Hub.
11. Inner bearing.
12. Grease seal.
13. Brake disc.
14. Disc retaining bolt (five off).
15. Sensor ring ABS.