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

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