Discovery 2. Manual — part 582

REAR AXLE

REPAIRS

51-5

REPAIRS

Differential - assembly

$% 51.15.01

Remove

1. Raise rear of vehicle.

WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.

2. Drain oil from differential.

+

MAINTENANCE, PROCEDURES,

Front and rear axle.

3. If same components are to be refitted,

reference mark propeller shaft and mating
components.

4. Remove 3 nuts and bolts securing flexible

coupling to pinion flange. Release propeller
shaft and tie aside.

5. Using tool LRT-51-008, extract the centralising

peg from the pinion flange. Remove the
centralising peg from the tool.

6. Remove LH and RH rear brake discs.

+

BRAKES, REPAIRS, Brake disc -

rear.

7. Disconnect each ABS sensor multiplug.
8. Release each harness from brake hose and

hose bracket.

9. Remove 4 bolts securing each rear wheel hub

to rear axle.

M51 0041B

5

4

M51 0056

LRT-51-008

REAR AXLE

51-6

REPAIRS

10. Release and remove wheel hubs and drive

shafts from rear axle. Remove and discard 'O'
rings from wheel hubs.

11. Remove 10 bolts securing differential to axle.

Release and remove differential from axle.

Refit

1. Clean drive shafts, wheel hubs and wheel hub

locations in rear axle.

2. Using a suitable solvent, clean old RTV sealant

from differential and axle mating faces.

3. Apply RTV sealant to differential or axle mating

face.

4. Apply Loctite 243 to threads of differential

securing bolts.

5. Fit differential to axle, fit bolts and tighten to 55

Nm (41 lbf.ft).

6. Clean pinion flange and centralising peg.
7. Using a tubular drift, fit centralising peg to

pinion flange. Ensure that the large diameter
part of the centralising peg is below pinion
flange mounting surface.

8. Position propeller shaft and align reference

marks.

9. Fit nuts and bolts securing flexible coupling to

pinion flange and tighten to 76 Nm (56 lbf.ft)

10. Lubricate 2 new wheel hub 'O' rings with clean

differential oil.

+

CAPACITIES, FLUIDS AND

LUBRICANTS, Lubrication. Install 'O' rings on
wheel hubs.

11. Fit LH and RH drive shafts and wheel hubs to

rear axle. Fit wheel hub bolts and tighten to 100
Nm (74 lbf.ft).

12. Connect each ABS sensor multiplug and

secure harness to harness bracket and brake
hose.

13. Fit LH and RH rear brake discs.

+

BRAKES, REPAIRS, Brake disc -

rear.

14. Remove stand(s) and lower vehicle.
15. Fill differential with oil.

+

MAINTENANCE, PROCEDURES,

Front and rear axle.

M51 0042B

REAR AXLE

REPAIRS

51-7

Seal - differential pinion

$% 51.20.01

Remove

1. Raise rear of vehicle.

WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.

2. Reference mark rear propeller shaft for

reassembly.

3. Remove 3 nuts and bolts securing flexible

coupling to pinion flange. Tie propeller shaft
aside.

4. Using tool LRT-51-008, extract the centralising

peg from the pinion flange. Remove the
centralising peg from the tool.

5. Using tool LRT-51-003 to restrain pinion

flange, remove bolt and washer securing pinion
flange. Remove pinion flange.

6. Position container to catch oil spillage

7. Using a suitable lever, remove pinion oil seal.

Take care to avoid damage to oil seal
recess.

M51 0043A

2

3

M51 0056

LRT-51-008

M51 0047A

LRT-51-003

REAR AXLE

51-8

REPAIRS

Refit

1. Clean pinion oil seal recess and pinion flange.
2. Lubricate oil seal lip with clean differential oil.

+

CAPACITIES, FLUIDS AND

LUBRICANTS, Lubrication.

3. Using tool LRT-51-010, fit pinion oil seal.

4. Fit pinion flange and securing bolt and washer.

Using tool LRT-51-003 to restrain pinion
flange, tighten pinion flange securing bolt to
100 Nm (74 lbf.ft).

5. Using a tubular drift, fit centralising peg to

pinion flange. Ensure that large diameter part of
centralising peg is below pinion flange
mounting surface.

6. Position propeller shaft and align reference

marks.

7. Fit nuts and bolts securing flexible coupling to

pinion flange and tighten to 76 Nm (55 lbf.ft).

8. Remove stand(s) and lower vehicle.
9. Check differential oil level.

+

MAINTENANCE, PROCEDURES,

Front and rear axle.

M51 0047A

LRT-51-003