Land Rover Defender 90 110 Workshop Book 3 Rover

							REAR DIFFERENTIAL -NINETY 
FRONT  DIFFERENTIAL - NINETY AND ONE TEN E1 
.. .... - ., . .,. ..~H: ., . . ...,. ,.. ... .. 
. 
ST508M 
13. Remove the bolts  and  washers securing the crown 
wheel 
to the  differential  flangc.  Withdraw the 
crown  whecl. 
14. Remove the differential carrier  bearings. 
15. Remove  the circlips  securing  the  differential cross 
shaft. Extract the  cross shaft. 
16. Withdraw thc differential  gears and pinions. 
17. Thoroughly clean  all components. 
ST509M 
INSPECTION 
18. Check  all bcarings for wear and/or pitting. 
19. Check  all gears  for wear,  scuffing,  pitting and 
damaged  teeth. 
20. NOTE. The crown  wheel and pinion  are supplied  as 
a  matched  set, also  the pinion  housing  and bearing 
caps. 
ASSEMBLE 
Differential  gears 
21. Fit the differential gears to the  differential  housing. 
22. Fit the differential  cross shaft and retaining  circlips. 
STSIOM 
23. Check the gear  for freedom  of rotation  and 
backlash.  Nominal  backlash  should 
be present. 
Excessive  backlash 
will necessitate renewal of the 
gears 
and/or the differential  housing. No provision 
is  made 
for backlash  adjustment. 
24. Check that the serial  number  marked on the  pinion 
end  face 
matchcs that marked  on the  crown wheel. 
7-5. Ensuring  that the differential  housing  flange  and 
crown  wheel 
are, thoroughly  clean fit the crown 
wheei. Fit the cmwn wheel  bolts  and  washcrs  and 
evcnly tighten. 
26. Fit the carrier  bearings  using a suitable press or 
drift and assemble  the tracks to the bearings. 
25 
26 
ST511 M 17  
						

							51 
27. Place the differential  housing complete with crown 
28. Fit the bearing  caps  and bolts. Do not fully tighten 
29. Fit the bearing  adjusting  nuts and  adjust to obtain 
30. Tighten the bearing cap bolts. 
wheel 
and bearings 
in the pinion  housing. 
the bolts. 
zero  end
-float. 
REAR  DIFFERENTIAL - NINETY 
FRONT DIFFERENTIAL -NINETY AND ONE TEN 
LI ST512M 
31. Using a dial  gauge  check thc crown  wheel for 
run
-out.  This  should  not exceed 0,10 mm 
(0.004 in). If excessive  run-out is recorded  remove 
the  crown  wheel and  examine  crown  wheel and 
mounting  flange  for 
burrs, grit, etc.  Refit  the 
crown  wheel  and  recheck.  Run
-out,  attributable  to 
a  buckled 
or damagcd differential  housing  flange 
can  be  corrected  only by renewing  the differential 
gear  housing. 
32. When  satisfied  that  run-out is within the specified 
limits  remove  the differential  housing from the 
pinion housing. 
33. Remove  the crown  wheel bolts and refit  them  using 
Loctite  Studlock. 
Evcnly tighten  the bolts to the 
correct  torque. 
ST514M 
36. Fit the  pinion  head bearing to thc pinion  using 
service 
tool 18G 47-6. 
4 
w 
37. Enter  the pinion  into its location in the  pinion 
housing. 
Do not fit the shims for  bearing pre-load 
at  this  stage. 
38. Fit the  outer  bearing  and spaccr. 
39. Fit the driving  flange, washer  and nut. 
34. Fit the pinion  head  bearing  track  and the  original 
shim  to the  pinion  housing  using service 
tools 
RO 262757A and RO 262757-1. If the original 
shim  was damaged 
or mislaid  use  a new  shim  of at 
least 
1,27 mm (0.050 in) thickness. 
35. Fit the  pinion  outer bearing  track to the  pinion 
housing  with service  tool 
KO 262757A and 
RO 
262757-2. 
NOTE: Instructions 34 and 35 are  carried  out in one 
operation 
as illustrated. 
18 
continued  
						

							REAR DIFFERENTIAL - NINETY 
FRONT  DIFFERENTIAL 
-NINETY  AND ONE TEN 
.. _,. . .... . .., :: ..., ..,./.,i; . .. ..:I 
ST516M 
ST517 
Drive  pinion  adjustment 
45. Ensure  that the pinion  end face  is free  of raised 
burrs  around 
the etched  markings. 
46.  Remove  the keep  disc from  the magnetised  base of 
dial  gauge  tool 
18G 191. 
47. Place the dial  gauge  and setting  block on a flat 
surface  and zero  the dial  gauge  stylus 
on the setting 
block. 
NOTE: The  setting  block  has  three setting  heights 
as  follows: 
39,50 mm Rationalised  axle 
38,10 mm Pre-Rationalised  axle 
30,93 mm Salisbury axle 
Ensure  that  the  height marked 
39,50 mm is used 
for 
this differential. 
40. 
Do not  fit the oil seal  at this  stage. 
41.  Tighten 
the pinion  flange nut slowly until the force 
required  to  rotate the pinion is 23 
to 40,25 kgf cm 
(20 to  35  Ibf  in).  This  will pre-load  the bearings  in 
order 
to check  the pinion  height dimension. 
NOTE: If using original  bearings,  which are bedded 
in,  the  pre
-load  figure is 11,5 to 17,25 kgf cm (10 to 
15 in Ib). 
. 
.I. . .. 
Drive  pinion  markings 
42. The markings  on the end  face adjacent  to the  serial 
number  are of no  significance  during servicing. 
43. The figure  marked on the end face  opposite  to the 
the deviation  from  nominal  required to correctly 
set  the  pinion. 
A pinion  marked  plus (+) must be 
set below nominal, a minus (-1 pinion must be set 
above nominal.  An unmarked  pinion  must  be set  at 
44.  The  nominal  setting dimension  is represented  by 
the  setting  gauge  block 
18G 191-4 which  is 
referenced from 
the pinion  end  face  to the bottom 
radius 
of the  differential bearing  bore. 
seripl number indicates, in thousandths of an  inch, ST518M 
48. Position the dial gauge centrally on the pinion end 
face  with  the stylus registering on the  lowest point 
on  one  differential  bearing  bore.  Note the dial 
gauge deviation from  the zeroed setting. . . .I-. .., nominal. ,I .. 
43 
I I continued 
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19  
						

							REAR DIFFERENTIAL - NINETY 
FRONT  DIFFERENTIAL - NINETY  AND ONE TEN 
49. 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 
equivalent 
to the  addition  thickness  of shims 
required  to  bring  the pinion  up 
to the nominal 
position. 
50. Before  adjusting  the shim  thickness,  check the 
pinion  face  marking and 
if it  has a plus (+) figure, 
subtract  that  amount 
in thousandths of an  inch 
from  the shim  thickness 
figure obtained 
in the 
previous  item. 
51. Alternatively, if the pinion  has  a minus (-) figure, 
add  the amount  to the shim thickness  figure. 
Adjust 
the shim  thickness  under  the  pinion head 
bearing  track as necessary. 
52. Recheck  the pinion  height  setting. If the  setting is 
correct,  the  mean reading  on  the dial 
gaugc will 
agree  with the figure  marked  on the  pinion  end 
face. 
For example,  with an end  face  marking of +3, 
the dial  gauge  reading  should  indicate that  the 
pinion  is 
+0.003 in. 
- 
58. Tighten  the pinion  flange  nut to the specified 
torque.  The force  required 
to rotate  the pinion 
shaft  should 
be within 23 to 40,25 kgf cm (20 to 
35 Ibf in) when  initial  inertia  has been  overcome. 
Change 
the bearing  pre-load shim  as necessary  to 
obtain  this requirement.  A thicker  shim will reduce 
pre
-load;  a thinner  shim will increase  prc-load. 
NOTE: If using  original  bearings,  which are bedded 
in,  the  pre
-load  figure is 11,5 to 17,25 kgf cm (10 to 
15 in Ib). 
59. Remove  the pinion  flange. 
Fitting  Pinion Oil Seal -latest type FRC  8220 
CAUTION 
A - When  fitting  the latest  type oil seal 
FRC  8220 
in place  of the  early  type FRC 4586 the latest 
mudshield  FRC 
SI54 must be fitted  in place  of the  early 
type  236072. 
Also seal replacer ISG 1382  must  be used  to fit  the  early 
type  oil seal  FRC  4586.  This 
tool must not be used to fit 
latest  seal FRC  8220. 
CAUTION B - Before  fitting the new  seal to the 
differential,  examine the seal  to ensure  that it is  clean, 
undamaged  and that  the garter  spring 
is properly 
located. 
A small  scratch  on the  seal  lips could  impair  its 
efficiency. 
60. Coat thc outer diameter of the  new  seal with  an 
all-purpose grease  and fit the seal,  lip side  leading 
squarely  on the  pinion  nose  housing  and  drive  the 
seal  into position  flush  with 
the end face  of the 
Bearing  pre-load adjustment 
53. Remove  the  pinion flange,  pinion, outer bearing 
and  spacer. 
54. Slide new shims, of the  same  thickness  as the 
originals  (bearing  pre
-load) into position  on the 
pinion  shaft. If the  original  shim  was  damaged 
or 
mislaid use a new shim of at least 4,06 nim 
(0.160 in) thickness. 
55. Enter  the  pinion in its  location in the pinion 
housing and 
fit the  outer  bearing  and spacer. 
56. Fit the driving  flange, washer and  nut. 
57. Do not fit the oil seal  at this stage. 
61. 
housing  using seal  replacing tool LST 106 
RR968M Lightly lubricate the seal lips  with EP90 oil. Fit the 
distancc piecc and flange  and secure with washer 
and 
nut. Tighten  the nut to the specified  torque 
and 
fit a new split  pin. 
ST1405M 
20  
						

							REAR DIFFERENTIAL - NINETY FRONT DIFFERENTIAL - NINETY AND ONE TEN 
?;::;:$ ,:-:. 62. Place  the differential  housing in the pinion 
63.  Fit the bearing  caps and bolts. 
Do not fully  tighten 
64. Fit the bearing  adjusting  nuts. 
housing. 
the 
bolts. 
?I .a. “Wi’ ,’ ..;::,.::# ”.?N 
51 
ST522M 
T I, ’ 
65 Using  service tool 530105,  slacken the lcft hand 
bearing  adjustment  nut  (as illustrated)  to produce 
end float. 
66. Tighten  the right  hand  nut  until  crown wheel/ 
pinion backlash  is just  removcd. 
66 
ST523M 
.. ...... :., ...... ,.. .... ..... 
DATA 
67. Tighten  the left hand  nut slowly until  it contacts the 
bearing.  Continue  turning  the  left
-hand nut until a 
backlash 
of 0,10 to 0,17 mm (0.004 to 0.007  ins) is 
achieved. 
Do not  slacken  the right-hand nut at any 
time,  otherwise 
thc bearing  preload will be 
affected. 
68. Fit the  locking  fingers  and roll pins. If necessary, 
tighten  the  adjustment  nuts slightly 
to align  the 
locking  finger with a slot. 
69.  Evenly  tighten  the  bearing  cap bolts  to the 
70. Rcchcck  crown whecl/pinion backlash. 
71. Lubricate  the bearings  and gears. 
specified 
torque. 
Pinion  bearing pre
-load ........................................ 23 to 40,25 kgf cm (20 to 35  Ibf  in) 
Crown 
wheel/pinion backlash ................................ 0,10 to 0,17 mm (0.004  to 0.007  in) 
Crown wheel 
run
-out ........................................... 0,10 mm (0.004 in) 
5.. > :..: .: .. ..., ‘2, , . ’ :... .. 
21  
						

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