Defender 300Tdi (1996+). Instruction - page 47

REAR AXLE AND FINAL DRIVE

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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. Using LTR-51-003 to 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. Using LRT-51-502, extract pinion inner bearing

cup and shim washers from casing. Note shim
washer thickness. .

36. Extract pinion outer bearing cup from casing

using LRT-51-502.

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37. Using LRT-51-500 and press LRT-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, using LRT-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.

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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 replacer LRT-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 replacer LRT-51-505,

detail 1, onto LRT-99-502 and secure with fixing
nut.

69. Hold still centre screw and turn butterfly lever to

draw in bearing cups.

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70. Press inner bearing cone onto drive pinion using,

LRT-51-502 details 1 and 2 and press
LRT-99-002.

71. Position pinion and bearing in casing; omit

collapsable spacer at this stage.

72. Fit outer bearing cone onto pinion.
73. Fit coupling flange and plain washer and loosely

fit flange nut.

74. Tighten coupling flange locknut to remove

end-float from pinion.

75. Rotate pinion to settle bearings and slowly

tighten flange locknut. Use a spring balance to
obtain a torque resistance of 11 Kgf/cm (18
lbf/in) to rotate pinion.

Drive pinion markings

76. Check that serial number marked on pinion end

face matches that marked on crown wheel.

77. The markings on end face adjacent to serial

number are of no significance during servicing.

78. The figure marked on end face opposite to serial

number indicates, in thousandths of an inch,
deviation from nominal required to correctly set
pinion. A pinion marked plus (+) must be set
below nominal, a minus (-) pinion must be set
above nominal. An unmarked pinion must be set
at nominal.

79. The nominal setting dimension is represented by

setting gauge block 18G191P or LRT-54-503,
which is referenced from pinion end face to
bottom radius of differential bearing bore. The
latter gauge is illustrated following instruction 85.

Drive pinion adjustment

80. Ensure that pinion end face is free of raised

burrs around etched markings.

81. Remove keep disc from magnetized base of dial

gauge tool 18G191.

82. Place dial gauge and setting gauge 18G191P or

LRT-54-503 on a flat surface and zero dial
gauge stylus on to setting gauge.

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