Defender 90 / 110 / 130. Instruction - page 95
PRO
PELLER S
HAFTS
OVERHAUL PROPELLER SHAFTS
Dismantle
1. Remove the propeller shaft from the vehicle
2. If a gaiter encloses the sliding member release the
two securing clips. Slide t h e gaiter along the shaft
to expose the sliding member.
3. Note the alignment markings on the sliding
member and the propeller shaft.
note following
instruction
3
4. Unscrew
the
dust cap and withdraw the sliding
member.
5 .
Clean and
the splines
for wear. Worn
splines
or excessive back-lash will necessitate
shaft renewal.
6.
Remove paint, rust, etc. from the vicinity
of the
universal joint bearing cups and circlips.
NOTE: Before dismantling the propeller shaft joint,
mark the position of the spider pin lubricator relative to
the journal yoke ears to ensure that the grease nipple
boss is re-assembled in the correct running position
to
reduce the possibility of
7.
Remove the circlips, and grease nipple.
00
3 M
8.
Tap the yokes to eject the bearing cups.
9. Withdraw the bearing cups and spider and discard.
10. Repeat instructions
5
to
8 at opposite end of
11.
Thoroughly clean the
and bearing cup
propeller shaft.
locations.
M
Assemble
12. Remove the bearing cups from the new spider.
13. Check that all needle rollers are present and are
properly positioned in the bearing cups.
14. Ensure bearing cups are one third full of fresh
lubricant. See Lubrication chart.
15. Enter the new spider complete with seals into the
yokes of the sliding member flange. Ensure that
the grease
hole faces away from the flange.
16.
Partially insert one bearing cup into a flange yoke
and enter the spider trunnion into the bearing cup
taking care not to dislodge the needle rollers.
17. Insert the opposite bearing cup into the flange
yoke. Using a vice, carefully press both cups into
place taking care to engage the spider trunnion
without dislodging the needle rollers.
18. Remove the flange and spider from the vice.
19. Using a flat faced adaptor
of
slightly smaller
its respective yoke until they reach the lower land
of the circlip grooves.
Do not press the bearing
cups below this point or damage may be caused to
the cups and seals.
diameter than the bearing cups press each cup into
PROPELLER SHAFTS
20. Fit the circlips.
21. Engage the spider i n the yokes of the sliding
member. Fit the bearing cups and circlips as
described in instructions
15 to 20.
22. Lubricate the sliding member spines and
fit the
sliding member to the propeller shaft ensuring that
the markings on both the sliding member and
propeller shaft align.
NOTE. The Universal joints on the front propeller
shaft are, by design, not assembled in-line with one
another. Nevertheless, the alignment marks on the
sliding member and propeller shaft must coincide
when assembling.
23. Fit and tighten the dust cap.
Fit the grease nipples to the spider and the sliding
member and lubricate.
25. Slide the gaiter (if fitted) over the sliding member.
26. Locate the sliding member in the mid-position of
its travel and secure the gaiter clips. Note that the
gaiter clips must be positioned at
180" to each other
so that they will not influence propeller shaft
balance.
26
ST
27. Apply instructions
15 to 20 to the opposite end of
28.
Fit the grease nipple and lubricate.
29. Fit
propeller shaft to the vehicle.
the propeller shaft.
2
REAR DIFFERENTIAL -
NINETY HEAVY DUTY
OVERHAUL REAR AXLE DIFFERENTIAL
7. Remove the split pin securing the pinion flange
(option)
8. Remove the pinion flange n u t using service tool
Service tools:
1205 flange holder tool;
191 pinion height setting gauge;
191-4 universal setting
47-6 pinion head bearing
1382
oil seal replacer;
RO
extractor for pinion bearing caps;
RO
262757-1 replacer - use with
RO
RO 262757-2 adaptor tail bearing cap replacer;
RO 530105 spanner
-
differential flange and carrier
bearing nuts;
RO 530106 bracket for dial gauge and indicator;
MS 47 press
.
ASSEMBLY
-
Land Rover Ninety Heavy Duty
nut.
1205, to
the flange.
DISMANTLE
is essential that differential components are marked
in their original positions and relative to other
components
so that, if refitted, their initial setting is
maintained. Note that the bearing caps must not be
interchanged.
1.
Remove the differential assembly from the axle.
2. Drift out the roll pin securing the bearing nut
locking fingers to the bearing caps. Remove the
locking fingers.
3.
Slacken the bcaring cap bolts and mark t h e caps for
reassembly.
4.
Using service tool R O
remove the bearing
adjusting nuts.
5. Remove the bearing cap bolts and bearing caps.
6.
Lift out the crown wheel, differential unit and
bearings.
9. Withdraw the pinion complete with pinion head
bearing and outer bearing shims. Withdraw the
shims.
10. Remove the pinion flange oil seal, spacer and
bcaring. Discard the oil seal.
9
11. Using service tool R O
the pinion
head bearing track and shim and drift out the outer
bearing track from the differential housing.
continucd
1
REAR DIFFERENTIAL -
NINETY
HEAVY
DUTY
18. Dismantle the pinions and crosspin assembly,
noting the relevant positions
of
all
components.
19. If required, extract the
bearings and place
them
in
relative outer tracks.
12. Remove the pinion head bearing with service tool
13.
For
purposes, add alignment marks
to
MS 47 and adaptor 18G
the crown wheel and differcntial case halves.
INSPECTING
WARNING:
avoid personal injury, the differential
assembly must be very securely retained while removing
the bolts from the crown wheel and case halves,
as these
damage.
bolts are Loctited and may be difficult
to remove.
21.
bearings must
press fit, except the flange
end pinion bearing, which must be a slide
fit
on
the
A
retaining fixture can be made from angle iron with
a
shaft.
and
bolts welded
it,
as illustrated,
that
when the
is clamped in
a vice, the differential
matched set and must
not
interchanged
assembly can be located over the
with the fixture
separately.
bolts between the case webs.
23. Bevel pinion housing and bearing caps are matched
sets and must not be interchanged separately.
14. Remove the crown wheel.
24. The differcntial case halves are a matched set and
Remove
screws holding
t h e
case halves
must not be interchanged separately. New screws
for
securing the case halves are already coated with
16. Withdraw the upper half of the casing.
a dry locking compound
and
do not require the
17. Withdraw the upper side gear. Note that there may
application
of Loctite. If
t h e
old
screws are being
reused,
threads must
cleaned and coated
with Loctite ‘Studlock’ just prior
to assembly.
together.
be thrust washers fitted t o the side gears.
2