Defender (1993+). Instruction - page 63
REAR AXLE
AND FINAL DRIVE
109.
Prevent the drive pinion from rotating and
check the crown wheel backlash
which
must
be 0,15 to 0,27 mm. If the backlash
is
not
within the
specified limits, repeat the
differential backlash checks, instructions 96 to
102 looking for possible errors.
110.
Fit
the differential cover and new gasket,
coating both sides of the gasket with Hylomar
112. Fit the rear axle assembly to the vehicle.
113. Replenish the differential lubricating oil, (see
114. Where major running parts have been
Lubrication chart). After the initial axle run,
replaced
during
servicing,
it
is
a
check the
oil
level and replenish as necessary
recommended practice to allow the axle
to
the filler/level plug hole.
assembly
to
'run in' by avoiding, where
possible, heavy loads and high speeds during
initial running.
DATA
Crown wheel backlash
...........................................................
0,15 to 0,27 mm
Differential bearings pre-load
.................................................
0,127 mm
Pinion height setting
...............................................................
Set using gauge 18G 191 P or 18G
191 -4
Torque resistance initial setting figures
Torque to
turn
drive pinion and new pinion bearings
Torque to
turn
drive pinion re-using the original bearings
OVERHAUL REAR AXLE DIFFERENTIAL
ASSEMBLY DEFENDER
90
The differential fitted to the rear axle on Defender 90
vehicles is identical to the differential fitted to the
front axle. For overhaul instructions refer to Section
54.
34,5 to 46 kgf cm
17,3
to
34,5
kgf cm
REAR
AXLE AND FINAL
DRIVE
REAR DISCS
REMOVE AND OVERHAUL REAR
HUBS
Remove and refit
Removing
MODELS WITH REAR DISC BRAKES
Service tools:
Oil seal replacer LST550-5
Drift for above tool MS550 or 18G134
Hub nut wrench 606435
Remove
1.
Jack-up the vehicle, lower on to axle stands
and remove the road wheels.
2.
Release the brake hose from the axle. casing
clips and remove the brake caliper retaining
bolts and secure the assembly
to
one
side.
Take care not to kink the brake hose
3. Remove the five bolts securing the axle shaft
to
the hub and withdraw the shaft.
4.
Bend back the lock tab and remove the outer
nut using box wrench 606435 and remove
-
remove the lock washer. Likewise remove the
inner nut.
5.
Remove the seal track spacer.
6. Withdraw the hub complete with bearing oil
seals and brake disc.
7.
Remove the inner and outer oil seals.
8. Remove the inner and outer bearing cones
(races).
9. Drive-out the inner and outer bearing cups.
1 .
Remove the rear hub assembly.
2.
Remove the rear disc fixing bolts.
3.
Tap
off
the disc from the rear hub.
Refitting
4.
Locate the disc onto the rear hub.
5.
Fit the disc fixing bolts. See Section 06 for
tightening torques.
6.
Using a dial indicator, check the total disc run
out, this must not exceed 0.15 mm (0.006 in).
If
necessary reposition the disc.
7.
Fit the rear hub assembly.
Disc
Reclamation
Check the disc thickness marked on the disc
boss-this dimension may be reduced to a minimum
thickness of 13 mm (0.510 in) front and 12 mm
(0.460 in) rear. by machining an equal amount off
both sides.
REAR AXLE
AND FINAL DRIVE
10.
Degrease and examine the hub and brake
14.
Fit
the new inner and outer bearing
cups
to
disc and
if
necessary replace both or
the hub, using a suitable
drift
or commercial
whichever part is unserviceable. The disc
I
S
bearing race driving tool.
attached to the hub with five bolts. Mark the
15.
Fit
the new inner bearing cone and pack with
relationship of the hub to the disc
if
the
one of the recommended hub greases.
original parts
are
to be re-assembled.
1 1 .
Examine the stub axle and
in
particular check
that the inner seal track
is
smooth and free
from blemishes.
12. If necessary remove the six retaining
bolts
and remove the stub axle complete with
the
mudshield and joint washer.
Fitting new
oil
seal-inner
Assemble
16. Clean the hub
oil
seal housing and ensure
that the seal locating surface is smooth and
13. Using
a
new
joint
washer fit the stub axle and
the chamfer
on
the leading edge is also
mud shield.
Coat
the threads of the retaining
smooth and free from burrs.
bolts with Loctite
270
and tighten evenly to
17. Examine
the
new seal and ensure that
it
is
me correct torque (see section 06-Torque
clean and undamaged and that the garter
values).
spring
is
properly
located.
Even a small
scratch
on
the
seal lip could impair its
efficiency.
18.
Although the new seal
is
already pre-greased
by
the
manufacturer, apply one
of
the
recommended hub bearing greases
to
the
outside diameter
of
the seal before fitting.
taking care not
to
damage the lip
Place
the
seal, lip side leading. squarely
on
the hub and using the 76 mm end
of
seal
replacer
tool
LST550-5 and drift
550
or
18G134. drive the seal into position. flush
with
the end face
of
the hub.
19
REAR AXLE AND FINAL DRIVE
26. Fit
the hub inner nut and using wrench
606435
tighten the adjusting nut while
slowly
revolving the hub until all end-float
I
S
removed. then back-off the nut approximately
half a turn and retighten the nut
to
13-15
in Ib
which will automatically allow for Compression
of the rubber on the new seal track spacer
giving the required hub end-float of 0.013 to
0.10
mm (0.0005
to
0.004
in).
27. If
the rubber on the seal track spacer has
previously
been compressed
the
hub
end-float can be checked
by
mounting a dial
indicator and bracket on the hub
so
that the
trace pin rests in a preloaded condition on the
nut. Rotate the hub to settle the bearings and
check the end-float by pushing and pulling the
hub. End-float must fall within the limits given
in the previous instruction.
28.
Fit a new lock washer and locknut.
Restraining the inner adjustment nut, tighten
the outer lock nut
to
70
to 80 ft Ib (95 to 108
Nm).
29.
If
original
components have been refitted
rotate the hub several times to settle the
bearings then recheck the end-float, refer to
previous note and instruction 27.
Fitting outer oil seal
20.
Fit the new outer bearing cone and pack with
one of the recommended hub greases. Carry
out instructions
16
to 18.
21.
Place the seal, lip side leading, squarely on
the hub and using the 72 mm end of seal
replacer tool LST550-5 and drift
550
or
18G134,
drive the seal into position
to
the
depth determined by the
tool.
22.
Coat the lips
of
both seals with one of the
recommended greases. This is important
since a dry seal can be destroyed during the
first few revolutions
of
the hub.
Fitting hub to stub
axle
23.
Select
a
new seal track spacer and check that
the outer diameter
is
smooth
and
free
from
blemishes
and
that
there
are
no
burrs on me
chamfered leading edge.
Taking care not to damage the seal lips fit the
hub assembly to the stub axle.
Do
not allow
the weight
of
the hub to rest even temporarily
on the outer seal
otherwise
damage and
distortion could occur. Therefore hold the hub
clear
of
the stub axle until the seal track
spacer is fitted.
25.
Carefully
fit
the seal track spacer, seal lip
leading.
24
30. Bend one segment of the lock washer over
the adjusting nut and another, diametrically
opposite, over the locknut taking care not to
damage the outer seal.
have
been
fitted
with
new
components
shaft and evenly tighten the retaining bolts of
throughout. If original components are being
the correct torque (see section 06-Torque
values)
.
refitted instruction 27 must be followed using the
adjustment nut to achieve the required end-float.
NOTE: Instruction 26 is applicable to hubs that
31. Using a new joint washer, fit the hub driving