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

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