Land Rover Defender Workshop 1993 Rover Manual
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3. Clean all intermediate gear components and Intermediate gear reassembly 7. Check for damage to the intermediate shaft 4. Fit new circlips into the intermediate gear thread and if necessary clean up with a fine 5. Using tools LST550 - 4 and MS550 fit bearing 8. Lubricate the taper roller bearing and intermediate gear shaft. 9. Insert new bearing spacer to gear assembly, followed by the taper roller bearings. lock plate. Check for damage or wear and replace as necessary. cluster, file or stone. tracks into the intermediate gear cluster. 10. Fit dummy shaft LST104 into the intermediate gear cluster. 11. Locate the gear assembly into the transfer box casing from the bottom cover aperture. 12. Insert intermediate shaft from the front of the transfer box casing, pushing the dummy shaft right through as shown and remove. (Making sure that the intermediate gear cluster meshes with the input gear and high range and low range gears.) 6. Fit the ‘O’ rings to the intermediate shaft and into the intermediate shaft bore at the front of the transfer box casing.
LT230T TRANSFER GEARBOX 13. Turn the intermediate shaft to allow fitting of 20. Peen the stake nut by carefully forming the retaining plate. collar of the nut into the intermediate shaft 14. Fit retaining plate and secure with retaining recess, as illustrated. bolt and washer. 15. Fit the intermediate gear shaft retaining stake CAUTION: A round nose tool must be used nut. for this operation to avoid splitting the collar of the nut. Power take - off cover - reassemble 21. Clean power take - off cover and gasket face. 22. Fit the two countersunk screws and tighten. 23. Remove the six bolts from the bearing support plate. 24. Apply sealant to the cover plate gasket and fit it to the bearing support plate. 25. Apply Loctite 290 to bolt threads and secure the power take - off cover with the six bolts and washers. Bottom cover - reassemble Adjusting intermediate gear torque - to - turn 26. Clean bottom cover and gasket face. 27. Apply sealant to cover gasket and fit to 16. Select neutral. transfer box casing. 17. Fit service tool LST105 to input gear and 28. Apply Loctite 290 to bolt threads and secure engage spline. 18. Tie a length of string to a split pin and fit to the service tool as shown. Attach the spring balance to the string. 19. To obtain the correct figures and to collapse the spacer within the intermediate gear cluster, tighten the intermediate shaft nut until the load - to - turn has increased by 3,7 kg (7 Ib) ± 1,63 kg (± 3 Ib) on that noted when checking input shaft load - to - turn. the bottom cover with SIX bolts and washers.
LT230T TRANSFER GEARBOX Differential lock switch adjustment Transmission brake drum - re-assemble. 1. Select differential locked position by moving 1. Clean brake backplate and oil catcher and the lock taper towards the right side of the apply sealant to the catcher joint face. transfer box casing. 2. Locate brake backplate on the rear output 2. Apply sealant to the differential lock warning housing with the brake operating lever on the light switch and fit to the top of the front right side of the transfer box casing. output housing. 3. Secure the backplate (including the oil 3. Connect a test lamp circuit to the differential catcher) with the four special bolts and tighten lock switch. using a hexagonal socket to the specified 4. Screw in the lock switch until the bulb is torque. illuminated. 4. Clean and fit brake drum and secure with two 5. Turn in the switch another half a turn and tighten with the locknut against the housing. 6. Disconnect the battery and move the differential lock lever to the left to disengage differential lock. 7. Clean the front output housing side cover. 8. Grease and fit side cover gasket. 9. Apply Loctite 290 to bolt threads, fit side cover and secure with seven bolts and washers. countersunk screws.
LT230T TRANSFER GEARBOX 13. Turn the intermediate shaft to allow fitting of 20. Peen the stake nut by carefully forming the retaining plate. collar of the nut into the intermediate shaft 14. Fit retaining plate and secure with retaining recess, as illustrated. bolt and washer. 15. Fit the intermediate gear shaft retaining stake CAUTION: A round nose tool must be used nut. for this operation to avoid splitting the collar of the nut. Power take - off cover - reassemble 21. Clean power take - off cover and gasket face. 22. Fit the two countersunk screws and tighten. 23. Remove the six bolts from the bearing support plate. 24. Apply sealant to the cover plate gasket and fit it to the bearing support plate. 25. Apply Loctite 290 to bolt threads and secure the power take - off cover with the six bolts and washers. Bottom cover - reassemble Adjusting intermediate gear torque - to - turn 26. Clean bottom cover and gasket face. 27. Apply sealant to cover gasket and fit to 16. Select neutral. transfer box casing. 17. Fit service tool LST105 to input gear and 28. Apply Loctite 290 to bolt threads and secure engage spline. 18. Tie a length of string to a split pin and fit to the service tool as shown. Attach the spring balance to the string. 19. To obtain the correct figures and to collapse the spacer within the intermediate gear cluster, tighten the intermediate shaft nut until the load - to - turn has increased by 3,7 kg (7 lb) ± 1,63 kg (± 3 lb) on that noted when checking input shaft load - to - turn. the bottom cover with six bolts and washers.
LT230T TRANSFER GEARBOX Differential lock switch adjustment Transmission brake drum - re-assemble. 1. Select differential locked position by moving 1. Clean brake backplate and oil catcher and the lock taper towards the right side of the apply sealant to the catcher joint face. transfer box casing. 2. Locate brake backplate on the rear output 2. Apply sealant to the differential lock warning housing with the brake operating lever on the light switch and fit to the top of the front right side of the transfer box casing. output housing. 3. Secure the backplate (including the oil 3. Connect a test lamp circuit to the differential catcher) with the four special bolts and tighten lock switch. using a hexagonal socket to the specified 4. Screw in the lock switch until the bulb is torque. illuminated. 4. Clean and fit brake drum and secure with two 5. Turn in the switch another half a turn and countersunk screws. tighten with the locknut against the housing. 6. Disconnect the battery and move the differential lock lever to the left to disengage differential lock. 7. Clean the front output housing side cover. 8. Grease and fit side cover gasket. 9. Apply Loctite 290 to bolt threads, fit side cover and secure with seven bolts and washers.
PROPELLER SHAFTS OVERHAUL PROPELLER SHAFTS 6. Remove paint, rust, etc. from the vicinity of Dismantle the universal joint bearing cups and circlips. NOTE: Before dismantling the propeller shaft 1. Remove the propeller shaft from the vehicle. joint, mark the position of the spider pin 2. If a gaiter encloses the sliding member lubricator relative to the journal yoke ears to release the two securing clips. Slide the gaiter ensure that the grease nipple boss is along the shaft to expose the sliding member. re-assembled in the correct running position to 3. Note the alignment markings on the sliding reduce the possibility of imbalance. member and the propeller shaft. See NOTE following instruction 22. 7. Remove the circlips, and grease nipple. 4. Unscrew the dust cap and withdraw the sliding member. 8. Tap the yokes to eject the bearing cups. 9. Withdraw the bearing cups and spider and discard. 10. Repeat instructions 5 to 8 at opposite end of propeller shaft. 11. Thoroughly clean the yokes and bearing cup locations. 5. Clean and examine the splines for wear. Worn splines or excessive back -lash will necessitate propeller shaft renewal.
PROPELLER SHAFTS 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 RECOMMENDED LUBRICANTS . 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 22. Lubricate the sliding member spines and fit yoke and enter the spider trunnion into the the sliding member to the propeller shaft bearing cup taking care not to dislodge the ensuring that the markings on both the sliding needle rollers. member and propeller shaft align. 17. Insert the opposite bearing cup into the flange yoke. Using a vice, carefully press both cups into place taking care to engage the spider trunnion without dislodging the needle rollers. 18. Remove the flange and spider from the vice. 19. Using a flat faced adaptor Of slightly smaller diameter than the bearing cups press each cup into its respective yoke until they reach the lower land of the circlip grooves. Do not press the bearing cups below this point or damage may be caused to the cups and seals. member. NOTE: The Universal joints on the front propeller shaft are, by design, not assembled in -line with one another. Nevertheless, the alignment marks on the sliding member and propeller shaft must coincide when assembling. 23. Fit and tighten the dust cap. 24. Fit the grease nipples to the spider and the sliding member and lubricate. 25. Slide the gaiter (if fitted) over the sliding 26. Locate the sliding member in the mid -position of its travel and secure the gaiter clips. Note that the gaiter clips must be positioned at 180° to each other so that they will not influence propeller shaft balance. 20. Fit the circlips. 21. Engage the spider in the yokes of the sliding member. Fit the bearing cups and circlips as described in instructions 15 to 20. 27. Apply instructions 15 to 20 to the opposite end of the propeller shaft. 28. Fit the grease nipple and lubricate. 29. Fit the propeller shaft to the vehicle.
REAR AXLE AND FINAL DRIVE REAR HUBS REMOVE AND OVERHAUL 17. Clean the hub oil seal housing and ensure that the seal locating surface is smooth and Special tools: the chamfer on the leading edge is also smooth and free from burrs. Oil seal replacer L.R.T.-550-5 Drift for seal replacer M.S. 550 or 18G134 18. Examine the new seal and ensure that it is L.R.T.-99-003 clean, undamaged and that the garter spring Hub nut spanner RO 606435A L.R.T.54-002 is properly located. Even a small scratch on the seal lip could impair its efficiency. Remove 19. Although the new seal is already pre-greased by the manufacturer, apply one of the 1. Jack -up the vehicle, lower onto axle stands recommended hub bearing greases to the and remove the road wheels. outside diameter of the seal, before fitting, 2. Remove the two brake drum retaining screws taking care not to damage the lip. and withdraw the brake drum. If necessary, 20. Place the seal, lip side leading, squarely on slacken the brake adjuster to facilitate the hub and using the 76 mm end of seal removal. replacer tool L.S.T.-550-5 and drift 550 or 18G 134 drive the seal into position to the depth Fitting inner oil seal 3. Prise-off the hub cap. 4. Remove the circlip. determined by the tool. 5. Remove the five bolts and withdraw the hub driving member and joint washer. 6. Prise -up the lock washer and remove the outer locknut and inner adjusting nut. 7. Withdraw the hub complete with with the inner and outer seals, seal track spacer, and inner and outer taper roller bearings. 8. If the stub axle is damaged or scored remove and discard it by removing the six brake back plate retaining nuts and bolts. Fitting outer oil seal 21. Fit the new outer bearing cone and pack with one of the recommended hub greases. 22. Carry out instructions 17 to 19 but insert the seal with the lip side trailing. 23. Place the seal, lip side leading, squarely on the hub and using the 72 mm end of seal replacer tool LS.T. 550-5 and drift 550 or 18 G 134, drive the seal into position to the depth determined by the tool. Overhaul hub 9. Remove the seal track spacer and outer seal. 10. Remove the outer bearing cone. 11. Remove the inner seal and bearing cone. 24. Smear the lips of both seals with one of the 12. If new bearings are to be fitted drift or press recommended greases. This is important out the old cups. since a dry seal can be destroyed during the 13. Degrease and examine the hub for cracks and first few revolutions of the hub. damage and renew if necessary. Renew hub if 25. Select a new seal track spacer and check that wheel studs are faulty. the outer diameter is smooth and free from blemishes and that there are no burrs on the 26. Taking care not to damage the seal lips fit the 14. If removed, fit the stub axle to the axle casing hub assembly to the stub axle. Do not allow with a new joint washer and secure with the the weight of the hub to rest, even six nuts and bolts and tighten to the correct temporarily, on the outer seal otherwise torque. damage and distortion could occur. Therefore 15. Fit new inner and outer bearing cups to the hold the hub clear of the stub axle until the hub, ensuring that they are drifted or pressed seal track spacer is fitted. squarely into position. 27. Carefully fit the seal track spacer, seal lip 16. Fit the inner bearing cone and pack with one leading. of the recommended hub greases. Fitting hub to stub axle Assemble chamfered leading edge.
REAR AXLE AND FINAL DRIVE NOTE: Instruction 28 is applicable to hubs that have been fitted with new components throughout. If original components are being refitted instruction 29 must be fallowed using the adjustment nut to achieve the required end-float. 28. Fit the hub inner nut and using wrench RO 606435 tighten the adjusting nut while slowly revolving the hub to seat the bearings and to remove all end-float, back-off the nut approximately half a turn and retighten the nut to 13-15 Ib in 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. 29. 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. 30. Fit a new lock washer and locknut. Restraining the inner adjustment nut, tighten the outer lock nut to 95 to 108 Nm. 31. 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 29. 32. Bend one segment of the locker washer over the adjusting nut and another, diametrically opposite, over the locknut. 33. Using a new joint washer, fit the hub driving member and secure with the five bolts and tighten evenly to the correct torque. 34. Fit the circlip to the axle shaft ensuring that it is properly seated in the groove. 35. Fit the hub cap. 36. Fit the road wheels and secure with the nuts. Jack -up the vehicle, remove axle stands and lower vehicle to ground. Finally tighten the road wheel nuts to the correct torque.
REAR AXLE AND FINAL DRIVE KEY TO REAR HUB COMPONENTS 1. Hubcap. 14. Locknut 3. Spring washer. hub driving member bolt. 15. Locknut. 4. Hub driving member. 16. Axle shaft 5. Hub driving member bolts. 17. Locknut. 6. Brake drum retaining screws. 18. Lock washer. 7. Outer bearing cone. 19. Joint washer. 9. Inner bearing cup. 21. Hub casting. 10. Inner bearing cone. 11. End -float adjusting nut. 23. Outer oil seal. 12. Inner oil seal. 24. Road wheel stud. 2. Circlip. 15. Bolt. 8. Outer bearing cup. 20. Seal track spacer. I 22. Brake drum. 13. Joint washer, 25. Stub axle.