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.

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