Defender (1993+). Instruction - page 67
FRONT AXLE AND FINAL DRIVE
position.
tighten the nut with just sufficient nip to
2.
Smear the outer diameter of the new seal with
remove any backlash between the crown
a recommended all purpose grease and with
the lip side leading, start it squarely into the
3. Line up the centre of the locking finger lug
pinion nose .housing. Using special service
with a slot in the adjusting nut. Fit the locking
tool L.S.T. 106, drive the seal home to the
finger and secure with the roll pin. Fit the
depth determined by the tool.
opposite nut and tighten, with the above
wrench, until resistance is felt.
3. Lubricate the seal lips with a recommended
axle oil. Check that the flange seal running
surface
is
clean, smooth and free
from
imperfections that could damage the seal.
Carefully fit the drive flange and secure with
the washer and nut. Tighten the nut to the
4.
Mount the pinion height setting gauge, with
correct torque whilst holding the flange with
the magnetic base on the pinion housing
restraining tool 18G 1205.
If
necessary
flange and the stylus resting against a crown
continue to tighten
the
nut to line up the split
wheel tooth. Continue
to
tighten the nut, on
pin hole and fit a new split pin.
the carrier side, until a backlash of 0,10 to
0,17 mm is achieved.
Do
not slacken the
crown wheel side
nut
otherwise the backlash
and bearing pre-load will be lost. Line
up
the
locking finger lug with a slot
in
the nut.
Adjust crown wheel and pinion backlash
1.
Return the pinion housing to the vertical
position and lower the crown wheel and
differential assembly into the pinion housing.
Lubricate the carrier bearings and fit the
tracks. Fit the bearing caps
so
that the
assembly marks line up and fit the bolts,
finger tight only.
2.
Move the crown
wheel
into mesh with the
pinion and
fit
the bearing adjusting nut on the
crown wheel side Using wrench RO 530105
wheel and pinion.
FRONT AXLE AND FINAL DRIVE
DISMANTLE
It
is
important that when dismantling the differential
the
relationship of the components are marked
relative
to
each other and
to
their position in the
pinion housing and differential carrier
so that
if
refitted, the original settings are maintained
to
avoid
the possibility of noise and premature wear of the
overhauled axle. In particular bearing caps and gears
must not be interchanged and new gears should
never be matched with worn ones.
1.
Drain the oil from the axle and refit and
tighten the drain plug. Withdraw the axle
shafts and remove the differential assembly
from the vehicle. Clean and degrease the
exterior
of the pinion housing and secure the
assembly in a vice in
a vertical position.
2.
Remove the two bearing nut locking fingers,
by driving out the retaining roll pins from the
6.
Reposition the pinion housing in the vice
so
that the pinion flange nut is accessible.
Remove the split pin
from
the
pinion
nut
and
using special service tool RO 1205 or the
reverse end
of
RO
530105,
to
restrain the
flange, remove the nut anticlockwise using a
bearing caps.
socket or ring spanner.
4.
Using special service tool RO 530105 or a
suitable alternative, unscrew the bearing nuts
anticlockwise.
7. Withdraw the pinion complete with the pinion
head bearing and shims.
8.
Also,
remove the oil seal, spacer and pinion
5. Lift-out the crown wheel and differential carrier
assembly together with the taper bearings and
tracks.
tail bearing.
bearing caps using a suitable punch.
3. Mark the caps in relation to the housing and
slacken the four bolts securing the two
FRONT AXLE AND FINAL DRIVE
9.
To remove the pinion head bearing track use
special service tool
RO 262757A ensuring that
the lower end of the tool locates in the
two
cut
outs in the housing. Using a ring spanner turn
the nut clockwise and draw out the track and
shim.
11.
Now that all the components have been
removed from the pinion housing, the main
assemblies can now be dismantled.
To
remove the pinion head bearing, secure the
press tool
M.S. 47 in the vice. Encircle the
bearing with the adaptor collets
18G
47-6
ensuring that the ends of the bearing rollers
locate against the internal shoulder of the
tool.
Insert the assembly into the press tool and
press the pinion
from the bearing. Remember
to hold the pinion to prevent
it
falling when
released from the bearing.
12.
Mark the relationship
of the crown wheel to
the differential carrier and firmly secure the
assembly in
a soft jawed vice. Remove the
ten
bolts
and washers and withdraw the crown
wheel from the carrier. Since the bolt threads
are secured with Loctite,
it
is
possible that
they will be tight for the entire length.
10.
Using a suitable drift, drive out the tail bearing
track locating the drift in the housing cut outs.
FRONT
AXLE
AND FINAL DRIVE
13.
Remove the carrier bearings with the general
purpose
tool 18G 2 or a suitable alternative.
It
is possible, however,
to
drift-off the bearing
from the gear housing side of the carrier by
positioning a drift in the two cast indentations
behind the bearing. The bearing on the crown
wheel side can
only
by withdrawn with a
puller.
17.
Clean and
degrease
all components ready
for
inspection. Clean the threads
of the crown
wheel bolts with a wire brush
to
remove the
old locking compound.
14.
To remove the differential gears, release one
of the
two
circlips securing the cross shaft
and push
out the shaft.
15.
Turn the gear assembly
90
degrees to enable
the two planet gears
to
be withdrawn through
the carrier aperture.
16.
Finally, remove the
two
sun gears.