Discovery 2. Manual — part 583

REAR AXLE

OVERHAUL

51-9

OVERHAUL

Differential assembly

$% 51.15.07

Disassembly

1. Remove differential assembly.
2. Secure differential assembly in a vice or stand.

3. Remove roll pins securing adjusting nuts, using

LRT 51-018-5 loosen adjusting nuts.

4. Reference mark bearing caps to aid assembly.

5. Remove bolts securing bearing caps and

remove caps.

6. Remove crown wheel assembly and collect

bearing outer races.

7. Mark outer races to bearings to aid assembly.

8. Using LRT-51-003 to restrain pinion flange

remove bolt and collect washer.

REAR AXLE

51-10

OVERHAUL

9. Remove pinion flange

NOTE: Older front differentials have a square
flange and an extra spacer fitted, this spacer
must be removed. Later front differentials have
a round flange but no spacer fitted.

10. Using a lever, remove pinion oil seal.

CAUTION: Take care to avoid damage to oil
seal recess.

11. Carefully tap pinion from bearings and collect

tail bearing.

12. Remove pinion tail bearing shim and record

shim size.

13. Using a bearing puller, remove pinion head

bearing.

14. Remove pinion bearing races.
15. Remove pinion head bearing shim and record

shim size.

REAR AXLE

OVERHAUL

51-11

16. Using a two legged puller and LRT 51-018/6,

remove the differential bearings.

17. Secure the crown wheel assembly in a vice.

18. Remove and discard 10 bolts securing the

crown wheel to carrier.

19. Carefully remove the crown wheel from the

carrier.

20. Remove and discard roll pin securing carrier

cross shaft and remove cross shaft.

21. Rotate gears to the open part of carrier and

remove planet gears.

22. Remove sun gears.

Inspect

1. Clean and inspect all components for wear and

damage.

2. Fit planet gears and rotate to align cross shaft

holes.

3. Fit cross shaft, ensure roll pin hole is aligned.
4. Secure cross shaft with new roll pin.
5. Fit crown wheel to carrier, fit new bolts and

tighten to 60 Nm (44 lbf.ft).

REAR AXLE

51-12

OVERHAUL

6. Ensure original head bearing shim is clean and

free from burrs and fit under bearing race.

7. Ensure pinion bearing cup recesses are clean

and free of burrs and using LRT-51-018-4 fit
pinion head and tail bearing races.

8. Fit pinion head bearing to pinion.
9. Lubricate bearings with thin oil.

10. Ensure original tail bearing shim is clean and

free from burrs and fit under bearing race.

11. Fit pinion and pinion tail bearing.
12. Fit pinion flange, washer and bolt.
13. Use LRT-51-003 to restrain pinion flange.
14. Tighten pinion flange bolt to 100 Nm (74 lbf.ft).
15. Check pinion for end float. Should read zero.

16. Rotate pinion several times to settle bearings,

check pinion Torque to Turn. Torque to Turn
should be recorded during pinion rotation.
Pinion Torque to Turn should be 4 to 6 Nm (3 to
4.5 lbf.ft).

17. Adjust size of tail bearing shim to obtain correct

pinion Torque to Turn (0.025 mm = 1 Nm
(0.001' = 0.7 lbf.ft) approximately).

18. Position LRT-51-018-7 on surface plate,

establish zero and reference DTI.

19. Ensure pinion height setting block, setting

gauge and mating faces are clean and free
from burrs.

20. Locate setting block LRT-51-018/11 over

pinion head, ensure it is fully seated in position.

21. Pinion height setting procedure:

l

'A' = Nominal pinion height setting, 74.390.

l

'B' = Setting block height.

l

'C' = Head height setting.

l

'C' = 'A' - 'B'. Subtract nominal pinion height
'A' from setting block height 'B' (on side of
setting block).

l

Example: 74.390 - 73.130 = 1.26 mm
(2.929' - 2.88' = 0.049'). Therefore pinion
head height reading is 1.260 mm

±

0.025

mm (0.049'

±

0.001').

CAUTION: Setting block height must be
checked using figures on side of block.