Range Rover Classic. Manual — part 86
51
REAR AXLE AND FINAL DRIVE
2
OVERHAUL
12. Remove pinion head bearing with service tool
LRT-99-002.
13. Remove bolts and washers securing crown
wheel to differential flange. Remove crown
wheel.
14. Remove differential carrier bearings.
15. Remove circlips and extract differential cross
shaft.
16. Withdraw differential gears and pinions.
17. Clean all components.
INSPECTION
18. Check all bearings for wear and pitting.
19. Check all gears for wear, scuffing, pitting and
damaged teeth.
20. Supplied as matched sets are: crown wheel and
pinion, pinion housing and bearing caps.
ASSEMBLE
Differential gears
21. Fit differential gears to differential housing.
22. Fit differential cross shaft and circlips.
REAR AXLE AND FINAL DRIVE
3
OVERHAUL
23. Check gear for freedom of rotation and backlash.
Nominal backlash should be present. Excess
backlash necessitates replacement of gears or
differential housing.
24. Check serial number marked on pinion end face
matches that on crown wheel.
25. Clean and fit crown wheel.
26. Fit carrier bearings and assemble tracks to
bearings.
27. Place differential housing with crown wheel and
bearings in pinion housing.
28. Fit bearing caps and bolts. Do not tighten bolts.
29. Fit bearing adjusting nuts and adjust to obtain
zero end float.
30. Tighten bearing cap bolts to
90 Nm.
31. Check crown wheel for run-out. This should not
exceed 0,10 mm. If exceeded examine crown
wheel and mounting flange for burrs, grit, etc.
Refit and recheck. A buckled or damaged
differential housing flange is corrected by
replacing differential gear housing.
32. After checking run out remove differential
housing from pinion housing.
33. Remove crown wheel bolts and refit using
Loctite ’Studlock’. Tighten to
58 Nm.
34. Fit pinion head bearing track and original shim to
pinion housing. Use service tools LRT-54-505
and LRT-54-506. If fitting a new shim use
minimum 1.27 mm thickness.
51
REAR AXLE AND FINAL DRIVE
4
OVERHAUL
35. Fit pinion outer bearing track to pinion housing.
Use service tools LRT-54-505 and LRT-54-507.
36. Fit pinion head bearing to pinion. Use service
tool LRT-54-502.
37. Fit pinion into its location without shims for
bearing pre-load.
38. Fit outer bearing, and spacer (front axle
differential only).
39. Fit driving flange, washer and nut.
40. Do not fit oil seal at this stage.
41. Tighten pinion flange nut until force required to
rotate pinion is
3 Nm if new bearings are fitted.
This will pre-load bearings to check pinion height
dimension.
NOTE: If using original bearings, pre-load
figure is 1.5 Nm.
Drive pinion markings
NOTE: Markings on end face adjacent to
serial number are of no relevance to
servicing.
42. Figures marked on end face opposite to serial
number show in thousandths of an inch,
deviation from nominal, required to set pinion.
Pinions marked plus (+) must be set below
nominal. Pinions marked minus (-) must be set
above nominal. Unmarked pinions must be set at
nominal.
REAR AXLE AND FINAL DRIVE
5
OVERHAUL
43. Nominal setting dimension is represented by
setting gauge block LRT-54-503. Referenced
from pinion end face to bottom radius of
differential bearing bore.
Drive pinion adjustment
44. Ensure pinion end face is free of burrs around
etched markings.
45. Remove keep disc from magnetized base of dial
gauge tool.
46. Place dial gauge and setting block on surface
plate. Zero dial gauge trace pin on setting block.
NOTE: Setting block has three height
settings heights.
Use 39.50mm setting mark for this differential.
Pinion height shims
PART No.
INCH
MM
FTC3853
.061
1.548
FTC3854
.060
1.523
FTC3855
.059
1.498
FTC3856
.058
1.473
FTC3857
.057
1.448
FTC3858
.056
1.423
FTC3859
.055
1.398
FTC3860
.054
1.373
FTC3861
.053
1.348
FTC3862
.052
1.323
FTC3863
.051
1.298
FTC3864
.050
1.273
FTC3865
.049
1.248
FTC3866
.048
1.223
FTC3867
.047
1.198
FTC3868
.046
1.173
47. Position dial gauge centrally on pinion end face,
register on lowest point on one differential
bearing bore. Note dial gauge measurement
from zeroed setting.
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