ECU LAND ROVER DISCOVERY 1999 Workshop Manual

PROPELLER SHAFTS
REPAIRS 47-5
REPAIRS
Propeller shaft - front
$% 47.15.02
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.If same components to be refitted, reference
mark propeller shaft and mating components.
3.Remove 8 nuts and bolts securing propeller
shaft to differential and transfer gearbox
flanges.
4.Remove propeller shaft.
Refit
1.Clean propeller shaft flanges and mating
faces.
2.Position propeller shaft to transfer gearbox
and differential and tighten nuts and bolts to 47
Nm (35 lbf. ft).
3.Remove stand(s) and lower vehicle.
Propeller shaft - rear
$% 47.15.03
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.If same components are to be refitted,
reference mark propeller shaft and mating
components.
3.Remove 4 nuts and bolts securing propellor
shaft to transfer gearbox flange.
4.Remove 3 nuts and bolts securing propeller
shaft to flexible coupling.
5.Remove propeller shaft.
Refit
1.Clean propeller shaft flanges and mating
faces.
2.Position propeller shaft to transfer gearbox and
flexible coupling.
3.Fit nuts and bolts securing propeller shaft to
transfer gearbox and tighten to 47 Nm (35
lbf.ft).
4.Fit nuts and bolts securing propeller shaft to
flexible coupling and tighten to 76 Nm (56 lbf.ft).
5.Lower vehicle.
M51 0043A
2
3

PROPELLER SHAFTS
REPAIRS 47-7
Flexible coupling
$% 47.20.08
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.If same components to be refitted, reference
mark flexible coupling and mating components.
3.Remove 3 nuts and bolts securing propeller
shaft to flexible coupling.
4.Move propeller shaft forwards to release from
flexible coupling and differential drive flange
spigot.
5.Tie propeller shaft aside.
6.Remove 3 nuts and bolts securing flexible
coupling to differential drive flange and remove
flexible coupling.Refit
1.Ensure flexible coupling, spigot and drive
flanges are clean.
2.Align the arrows on the flexible coupling with
the securing bolt positions as illustrated. Fit
flexible coupling to differential drive flange and
tighten nuts and bolts to 76 Nm (56 lbf.ft).
3.Fit propeller shaft to spigot and flexible
coupling. Tighten nuts and bolts to 76 Nm (56
lbf.ft).
4.Remove stand(s) and lower vehicle.

REAR AXLE
51-2 DESCRIPTION AND OPERATION
Description
General
The rear 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 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 rear suspension.
A differential cover on the rear of the axle casing contains an oil level plug for checking and replenishment of the
differential unit lubricating oil. A magnetic drain plug is installed on the underside of the axle casing.
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 between the chassis and the left rear wheelarch.
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 pinion flange which is secured with a bolt
and washer. An oil seal prevents leakage past the pinion flange.
Centralising peg
The centralising peg is a press fit in the centre of the pinion flange and provides a positive location for the rear
propellor shaft to ensure it is centralised with the flange.

REAR AXLE
DESCRIPTION AND OPERATION 51-3
Wheel hub
Section through wheel hub
1'O' ring
2Hub bearing
3Hub flange
4Wheel stud5Stake nut
6ABS sensor ring
7Drive shaft
8Axle casing
Each wheel hub consists of a hub flange pressed into a hub bearing.
The hub flange is splined to accept the outboard end 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 end of the axle casing. An 'O' ring seals the joint between the outer
race and the axle casing to prevent leakage of differential lubricating oil. 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.
Drive shaft
Each drive shaft consists of a solid rod, splined at both ends.

REAR AXLE
REPAIRS 51-5
REPAIRS
Differential - assembly
$% 51.15.01
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Drain oil from differential.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
3.If same components are to be refitted,
reference mark propeller shaft and mating
components.
4.Remove 3 nuts and bolts securing flexible
coupling to pinion flange. Release propeller
shaft and tie aside.
5.Using tool LRT-51-008, extract the centralising
peg from the pinion flange. Remove the
centralising peg from the tool.6.Remove LH and RH rear brake discs.

+ BRAKES, REPAIRS, Brake disc -
rear.
7.Disconnect each ABS sensor multiplug.
8.Release each harness from brake hose and
hose bracket.
9.Remove 4 bolts securing each rear wheel hub
to rear axle.
M51 0041B
5
4
M51 0056
LRT-51-008

REAR AXLE
51-6 REPAIRS
10.Release and remove wheel hubs and drive
shafts from rear axle. Remove and discard 'O'
rings from wheel hubs.
11.Remove 10 bolts securing differential to axle.
Release and remove differential from axle. Refit
1.Clean drive shafts, wheel hubs and wheel hub
locations in rear axle.
2.Using a suitable solvent, remove all traces
sealant from differential and axle mating faces.
3.Apply sealant, Part No. STC 3811 to differential
or axle mating face.
4.Apply sealant, Part No. STC 50552 to threads
of differential securing bolts.
5.Fit differential to axle, fit bolts and tighten to 55
Nm (41 lbf.ft).
6.Clean pinion flange and centralising peg.
7.Using a tubular drift, fit centralising peg to
pinion flange. Ensure that the large diameter
part of the centralising peg is below pinion
flange mounting surface.
8.Position propeller shaft and align reference
marks.
9.Fit nuts and bolts securing flexible coupling to
pinion flange and tighten to 76 Nm (56 lbf.ft)
10.Lubricate 2 new wheel hub 'O' rings with clean
differential oil.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication. Install 'O' rings on wheel hubs.
11.Fit LH and RH drive shafts and wheel hubs to
rear axle. 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.
13.Fit LH and RH rear brake discs.

+ BRAKES, REPAIRS, Brake disc -
rear.
14.Remove stand(s) and lower vehicle.
15.Fill differential with oil.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
M51 0042B

REAR AXLE
REPAIRS 51-7
Seal - differential pinion
$% 51.20.01
Remove
1.Raise rear 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 rear propeller shaft for
reassembly.
3.Remove 3 nuts and bolts securing flexible
coupling to pinion flange. Tie propeller shaft
aside.
4.Using tool LRT-51-008, extract the centralising
peg from the pinion flange. Remove the
centralising peg from the tool.5.Using tool LRT-51-003 to restrain pinion
flange, remove bolt and washer securing pinion
flange. Remove pinion flange.
6.Position container to catch oil spillage
7.Using a suitable lever, remove pinion oil seal.
Take care to avoid damage to oil seal
recess.
M51 0043A
2
3
M51 0056
LRT-51-008
M51 0047A
LRT-51-003

REAR AXLE
51-8 REPAIRS
Refit
1.Clean pinion oil seal recess and pinion flange.
2.Lubricate oil seal lip with clean differential oil.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Using tool LRT-51-010, fit pinion oil seal.
4.Fit pinion flange and securing bolt and washer.
Using tool LRT-51-003 to restrain pinion
flange, tighten pinion flange securing bolt to
100 Nm (74 lbf.ft).
5.Using a tubular drift, fit centralising peg to
pinion flange. Ensure that large diameter part of
centralising peg is below pinion flange
mounting surface.
6.Position propeller shaft and align reference
marks.
7.Fit nuts and bolts securing flexible coupling to
pinion flange and tighten to 76 Nm (55 lbf.ft).
8.Remove stand(s) and lower vehicle.
9.Check differential oil level.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.
M51 0047A
LRT-51-003

REAR AXLE
OVERHAUL 51-9
OVERHAUL
Differential assembly
$% 51.15.07
Disassembly
1.Remove differential assembly.
2.Secure differential assembly in a vice or stand.
3.Remove roll pins securing adjusting nuts, using
LRT 51-018-5 loosen adjusting nuts.
4.Reference mark bearing caps to aid assembly.
5.Remove bolts securing bearing caps and
remove caps.6.Remove crown wheel assembly and collect
bearing outer races.
7.Mark outer races to bearings to aid assembly.
8.Using LRT-51-003 to restrain pinion flange
remove bolt and collect washer.

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.