Defender (1993+). Manual — part 66

FRONT AXLE AND FINAL

DRIVE

50. Coat a joint washer both sides with sealing

63. Fit the stub axle with the keyway uppermost

compound and place in position on the lower

at 12 o'clock. At this stage

it

is most important

swivel pin.

to

ensure that the constant velocity joint

51.

Fit the lower pin with lip outboard.

Do

not

bearing journal engages fully into the bronze

secure with bolts at this stage.

bush in the rear

of

the stub axle before the

52. Lubricate the Railko bush with an EP oil and

stub axle is secured with bolts. Damage to the

Fit the top swivel pin with

existing shims and fit

bush can occur if this precaution is not

grasp the stub axle with one hand and with

53. Coat the threads of the lower swivel pin bolts

the other pull the axle shaft into the bush. The

with Loctite 270 and fit, together with the

shaft and bush are correctly engaged when

brake disc shield bracket, and tighten to 22 to

the end of the axle shaft splines are flush with

28 Nm.

the end

of

the stub axle. This condition must

54.

Tighten the top swivel pin securing bolts to 60

be maintained during all ensuing assembly

to

70

Nm.

operations.

55. To check the top swivel pin pre-load attach a

64.

Place the mud shield in position and secure

spring balance to the track-rod ball joint bore

the stub axle to the swivel pin housing with

and pull the balance to determine the effort

the six bolts using Loctite 270 and evenly

required to turn the swivel. The resistance,

tighten

to

60 to 70

Nm.

once the initial inertia has been overcome,

65.

To

complete

the

reassembly,

follow

should be 3,60 to 4,50 Kg.

If

necessary,

instructions 25 to

41

covering front hub

adjust by removing or adding shims to the top
swivel pin as required.

66.

Check that the swivel pin housing drain plug

the securing boIts and jump hose bracket (do

observed. To ensure proper engagement

overhaul.

is tightly fitted and remove the filler level plug.

67. Inject

approximately

0,28

litres

of

recommended

EP oil

until the oil begins to run

out

of

the filler hole. Fit and tighten the plug

and wipe away any surplus oil.

68. Set the steering lock-stop bolts to provide a

clearance between the tyre wall and radius
arm in accordance with the dimensions below.
This dimension however, must be set to 56
mm, irrespective

of

tyre size and type where

steering gaiters are fitted.

Tyre Size

750x1 6 Michelin XS

750x1

6 Avon Rangers

750x16 (All others)

Dim 'A' ± 0,25 mm

54,00

mm

54,00

mm

51.00

mm

56.

Liberally apply - but do not pack - a
recommended grease between the lips of the
swivel oil seal (2,5 to 4,0 grams).

57.

Secure the oil seal and joint washer with the
retaining plate and securing bolts tightening
evenly to 7

to

10 Nm.

58. Fit the track-rod and drag link and secure with

new split pins.

59.

Fit the brake disc shield.

60.

Loosely fit the lock stop bolt and nut for later
adjustment.

The clearance should be set to a minimum of 20 mm
on vehicles

fitted

with

205R X

16

or 600

X

16

tyres.

Fit drive

shaft and stub axle

61.

Place

a

new joint washer in position on the

swivel pin housing

to

stub axle mating face.

62.

Taking care not to damage the axle shaft oil

seals, insert the axle shaft, and when the
differential splines are engaged, push the

ST1801M

assembly

home

not tighten).

FRONT AXLE AND FINAL DRIVE

OVERHAUL FRONT AXLE DIFFERENTIAL

Special service tools

18G1205/LRT-51-003 Flange restrainer tool
18G 191 Pinion height setting gauge

18G191-4/LRT-54-503 Universal setting block
18G47-6/LRT-54-502

Pinion

head bearing

remover/replacer
LST106/L.R.T.-54-504 Oil seal replacer

RO

262757A/LRT-54-505 Extractor for pinion

bearing caps

RO

262757-1/LRT-54-506 Replacer, use with

RO262757A
RO262757-2/LRT-54-507 Adaptor, tail bearing cap
replacer

RO

530105/LRT-54-508 Spanner, diff, flange and

carrier bearings
RO 530106/LRT-99-503 Bracket for dial gauge
MS47/LRT-99-002 Press
18G2/L.R.T.-99-500 General purpose puller
MS103 Torque meter

FRONT AXLE AND FINAL

DRIVE

FRONT

AXLE AND FINAL DRIVE