Defender 90 / 110 / 130. Instruction - page 74
TRANSFER GEARBOX
Reassembling
34. Ensure that all faces
of t h e transfer box are clean.
Check that
and drain plugs are
in
position.
36. Fit the two studs which are used for part retention
of the extension housing.
37. Screw
in the ‘radial’ dowel. It is important that its
projecting blade is set
in
line
with the
tapped fixing hole centres
in the transfer box
casing.
46. Remove the speedometer driven gear and spindle
47. Remove the
ring and oil seal.
from the spindle housing.
Rear output shaft housing
-
Overhaul (Instructions 47
to 73)
Dismantling
38.
Using flange wrench
1861205 remove the flange
nut.
steel and felt washers.
NOTE: Ensure flange bolts are fully engaged in the
wrench.
38
48. Slide off the spacer and speedometer drive gear
from the output shaft.
49. Clean all parts, renew
oil
seals and Nyloc flange
nut and examine all
parts for wear or
damage, renew as necessary.
Reassembling
50. Press the output bearing into
t h e
housing. D o not
use excessive force. If necessary warm the housing
and case.
51.
Fit
the bearing retaining circlip using circlip pliers
186257.
52. Fit a new dual lip oil seal (open side inward), with
the seal in contact with the bearing circlip it
is
essential to use replacer tool 1861422.
NOTE: On early production two separate seals
were used, these should be replaced with the new
dual lip seal.
39. Remove the output shaft flange with circlip
attached. If necessary, use a two-legged puller.
NOTE: The circlip need only be released if the
flange bolts are to be renewed.
40. Remove the speedometer spindle housing. This
can be prised out with
a screw driver.
41. Remove assembly from vice and support the
housing to allow removal
of the shaft, drifting
it
out by striking the flange end
of the shaft.
driver in the
slot
provided.
1271.
retaining the bearing.
housing.
52
42.
the
catch
ring
screw
43. Prise out and discard the
using tool
44. Using circlip pliers
remove the circlip
45. Drift out the bearing from the back of t h e
M
25
TRANSFER GEARBOX
53.
Carefully charge the lips of the seal with grease.
54.
Fit
oil catch ring o n t o housing.
55.
Fit oil seal into speedometer spindle housing
(open side inwards) with a suitable
56.
Fit
ring to speedometer spindle housing.
57. Lubricate seal and
ring with
oil.
58. Locate speedometcr driven gear and spindle in
spindle housing and push into position.
59.
Slide speedometcr drive gear and spacer onto
output shaft.
60.
Fit output shaft to the bearing in the rear output
shaft housing.
Examine the flange seal track to check for any
damage that may harm the seal. Retain for fitting
later.
62. Locate speedometer spindle housing assembly in
the output shaft housing and push in flush with
housing face.
-NOTE: Before fitting the rear output shaft housing
to the transfer box casing the centre differential
rear bearing track must be fitted.
63. Drift the centre differential rear bcaring track into
the transfer box casing
in) below the
outer face of the casing. Check the depth before
proceeding.
Fitting rear output shaft housing to transfer box
64. Grease and
fit
housing gasket and locate the
housing in position
on
the transfer box.
NOTE: If the differential rear main bearing track
has been correctly fitted there will be a gap
between the housing face and the gasket at this
stage.
65.
Apply Loctite 290
to
the threads
of the six housing
securing screws, noting that the upper screw is
longer. Fit the screws (with spring washcrs)
evenly tightening them to the specified torquc.
This will press in
rear main bearing track to
the correct position and seat
Centre differential Unit
-
Overhaul
(Instructions 66 to
119)
Dismantling
66.
Detach
selector shaft and fork.
I
I
I
67. Using soft jaws secure the differential unit in a vice
with
t h e
‘stake’ nut uppermost.
68. Remove
the
metal to
removal
of
t h e
nut.
69.
Remove the ‘stake’ nut using tool
Remove the differential unit from the vice.
71. Secure hand press MS47 in vice with collars
and using button
remove
rear taper (twenty-four) roller bearing and collars
LST
47-1 for latest (twenty-three) roller bearing.
72. Substituting collars
remove front
taper roller bearing.
73. Remove the hand press from the vice.
ii
74. Remove the high range (smallest) differential
gear and its bush.
75. Mark the relationship
of the
selector
sleeve to the hub and remove the sleeve.
26
TRANSFER GEARBOX
*.I..
--
76.
Using
a suitable press behind the low range
(largest) gear carefully remove both
hub
and low range gear together. Alternatively, the
rear carrier bearing, high output gear and bush,
hub and sleeve and low output gear can
be pressed off
in one operation by supporting the
differential side of the low gear.
77.
Using
soft jaws secure the differential unit in the
vice by gripping the inner hub splines.
78.
Remove the eight retaining bolts and lift off the
front differential case.
79. Lift off the front (upper) bevel gear and thrust
washer.
80. Remove both pairs of side gears with their
respective shafts and dished washers together.
81. Lift out the remaining rear (lower) bevel gear and
thrust washer.
Remove the rear differential case from the vice.
83. Clean all parts, examine for wear or damage,
renew as necessary.
.
.
..
.
99
-
Obtaining differential backlash by checking bevel gear
end-float
84.
Using soft
jaws secure the rear differential case in
the vice by gripping the inner hub splines.
85. Ensure that all differential components are dry to
assist in checking end-float.
86. Using
a micrometer measure one of the bevel gear
thrust washers and note thickness.
87.
Fit the thrust washer and bevel gear to the rear
(lower) differential case.
88. Assemble the side gears and dished washers on
their respective shafts and fit to the rear case.
89. Measure the remaining bevel gear thrust washer,
noting its thickness.
90. Fit the thrust washer and bevel gear to the front
case.
91.
Fit and align the front differential case tightening
the eight securing bolts to the specified torque.
92. Ensure that the front bevel gear is fully in mesh by
tapping
i t
down, using
a punch through the front
differential case.
93. Measure the front bevel gear end-float with feeler
gauges through the slots provided
in
the
front
differential case. This must be between
and
(0.001 and 0.003 in) maximum.
94. Invert differential unit in vice and repeat the
above procedure (items
92
and 93) for the rear
bevel gear in the rear differential case.
95.
Return the differential unit to its former position
in
vice
i.e. with
t h e
front differentid case
uppermost.
.
27
TRANSFER
GEARBOX
96.
Remove the eight securing bolts and lift off the
Remove the
gears and thrust washers, and
98. Select correct thrust washers required for final
front differential case.
side gear
bly.
Reassembling
99. Fit the selected thrust washer and bevel gear to
the rear (lower) differential case.
100. Assemble the side gears and dished washers o n
their respective shafts and
fit
to the rear case.
101. Fit the other selected thrust washer and bevel gear
to the rear case.
102. Lubricate all parts with oil.
103. Fit and align the front differential casc, locate the
eight securing bolts and tighten to
specified
torque.
104. Finally check that the differential gears revolve
freely.
105. Place the front (outer) differential bearing on the
front differential case and press into position
using larger end
of tool
106. Invert the differential unit in the vice.
107. Fit t h e low range gear (largest) to
differential case (with its 'dog' teeth uppermost).
Press the
hub onto the splined area
of
the case. Check end-float
of low range gear. See
Data at end
of section.
109. Slide the
selector sleeve onto
hub
outer splines, observing the alignment marks.
110. Fit the bush into the high range (smallest) gear
and slide t h e bushed gear onto the rear
differential case.
end-float of high range
gear and running clearance of gear
on bush.
data at end
of section.
NOTE: If the clearances vary considerably from
those specified in the data the assembly must be
rebuilt.
111. Place the rear differential bearing on the rear
diffcrcntial case and press i n t o position using
t h e
smaller end of tool 1861424.
28
.,:;::-
-U'
112.
Fit the 'stake'
n u t
using tool
and tighten
to the specified torque.
113.
the nut flange into the slot provided.
114. Remove the differential unit from the vice.
115. Lubricate gears, bearings, sleeve and bush with
oil.
116. Clean and check
selector
fork
assembly for wear and
if
necessary.
117.
To renew the selector fork remove the square set
screw retaining
i t
to the selector shaft and ensure
any traces of Loctite are removed from the
threads.
118. Refit the selector fork
with
the fork boss towards
the three detent grooves. Align
hole
in
the
fork boss with the indent in t h e shaft nearest to
the detent grooves.
119. Apply Loctite 290 to the set screw threads and
fit
the set screw to the
torque.
Prop up the transfer box
so
that
its
front side
is
uppermost.
121.
Fit the selector fork
to
the
selector
122. Locate the differential assembly and
. ' ' -
selector fork assembly into the transfer casc. It
may be necessary to rotate the output shaft
to
ease fitment.
Fit the selector shaft detent ball and spring, apply
Loctite 290 to
t h e
detent plug threads, screw in
the detent plug until the spring is just coil bound,
then
back off two complete turns.
...
.
sleeve in the differential assembly.