Land Rover Defender 90 110 Workshop Book 3 Rover

L~230T TRANSFER BOX 137 I 
./ ..... . ,L;!-: 6. Fit the 0 rings to the intermediate  shaft and into 
the  intermediate  shaft  bore  at the front  of the 
transfcr  box casing.  13. 
Turn  the  intermediate  shaft  to allow  fitting  of 
14.  Fit  retaining  plate  and  secure with retaining  bolt 
15. Fit thc intcrmediate gear shaft retaining  stake nut. 
retaining 
plate. 
and  washer. 
- .,.. .. .... ,. .. ..- , . .. I .. , . . . . . . z.. :, 
Intermediate  gear reassembly 
7. Check for damage  to the...

LT230T TRANSFER BOX 
3- 
Power take-off cover - reassemble 
+- 
21.  Clean  power  take-off cover  and gasket facc. 
22. 
Fit the two  countersunk  screws and tighten. 
23.  Remove 
ihe six bolis from  the  bearing  support 
plate. 
24.  Apply sealant  to the  cover  plate  gasket  and 
fit it to 
the  bearing  support  plate. 
25.  Apply  Loctitc  290 to bolt  threads  and secure  the 
power  take
-off cover  with the six bolts  and 
washers. 
Bottom  cover - reassemble 
26. Clean bottom  cover and...

PROPELLER SHAFTS 147 I 
,. .;” 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 
the gaiter  along the shaft 
to expose  the sliding  member. 
3. Note the alignment  markings on  the sliding 
member  and the propeller shaft. 
Sec note  following 
instruction 
22. 
3 
STlOOOM 
4. Unscrew the dust  cap and  withdraw  the sliding 
member. 
STlOOlM 
5. Clean  and cxamine the...

47 
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 
nipple hole  faces  away from the flange. 
16. Partially  insert one bearing  cup into  a flange  yoke 
and  enter...

REAR DIFFERENTIAL - NINETY HEAVY DUTY -  ~~ 
OVERHAUL  REAR  AXLE  DIFFERENTIAL 7. Remove  the 
split  pin securing the pinion  flange 
(option) 8. Remove  the  pinion flange nut using service  tool 
Service tools: 
18G 1205 flange  holder  tool; 
18G 191 pinion  height setting  gauge; 
18G 191-4 universal  setting block; 
18G 47-6 pinion  head bearing removerlreplacer; 
18G 1382 oil seal replacer; 
RO 262757A extractor  for pinion  bearing  caps; 
RO 262757-1 replacer -use  with RO 262757A; 
RO 262757-2...

151 I REAR DIFFERENTIAL - NINETY HEAVY DUTY 
ST508M ST1202M  
18. Dismantle the pinions  and crosspin  assembly, 
noting  the relevant  positions 
of all components. 
19. If required,  extract the rollcl- bearings  and place 
them 
in thcir relative  outer tracks. 
12. 
Remove  the pinion  head bearing  with service  tool 13. For rcasscmbly purposes,  add alignment  marks to 
MS 47 and adaptor 18G 47-6. 
the crown  wheel and differcntial  case halves. 
INSPECTING WARNING: To avoid  personal  injury, the...

REAR DIFFERENTIAL -NINETY HEAVY DUTY 
~2,-~; ASSEMBLY .I ,> 1- %.A NOTE: If thrust washers  were removed  from the side 
gears  during  dismantling,  the washers  must be 
lubricated  with EP90  oil and  refitted  during the 
following  procedure. 
DO NOT allow oil to contact any 
holes  or bolts  that are to be  Loctited. 
51. 
25. Position the smaller  case half with the open  side 
uppermost  and 
fit the side  gear  into the case. 
26.  Assemble  the crosspins,  pinions and  thrust 
washers,...

REAR DIFFERENTIAL - NINETY HEAVY DUTY 
44. Enter  the  pinion  in its  location in the  pinion  51. The nominal setting dimension  is represented  by 
referenced  from the pinion  end face  to the  bottom 
radius 
of the  differential  bearing bore. 
housing. 
Do not 
fit the  shims  for bearing pre-load  the setting  gauge  block 18G 191-4  which  is 
at this stage. 
45. Fit  the  outer bearing  and spacer. 
46. Fit the driving  flange,  washer and nut. 
Drive  pinion  adjustment 
47. Do not fit the oil...

REAR DIFFERENTIAL - NINETY HEAVY DUTY 151 I 
;::-,:;: 56. Repeat on the other bearing  bore. Add together 
the  readings  then halve  the sum  to obtain  the mean 
reading.  Note whether  the stylus  has  moved up 
or 
down from  the zeroed  setting. 
a.Where the stylus  has moved  down,  the  amount is 
equivalent 
to the thickness of shims  that must  be 
removed  from  under the pinion inner track 
to bring 
the  pinion  down to the nominal  position. 
b.Where the stylus has  moved  up, the amount  is...

El REAR DIFFERENTIAL - NINETY  HEAVY DUTY 
69. Place  the  differential  housing in the pinion 
70. 
Fit the  bearing  caps and bolts. Do not fully tighten 
71. 
Fit the  bearing  adjusting nuts. 
housing. 
the bolts. 
76. 
Evenly tighten the  bearing  cap bolts  torque 
77.  Recheck crown 
wheel/pinion backlash. 
78.  Lubricate  the bearings  and gears. 
* 8,3 kgf m (60 Ibf ft) (82 Nm). 
72  Using  service tool R0530105, slackcn the left  hand 
bearing  adjustment 
nut (as illustrated)  to  produce 
end...