rear axle - landy
TRANSCRIPT
$1;; 1987 REAR AXLE & FINAL DRIVE
REAR AXLE
Remove and Refit
Removing
WARNING: The removal and refitting of the axlefrom the vehicle requires the assistance of afurther two personnel to steady the axle, whenlowering or repositioning the axle.
1. Drain the brake system.2. Jack-up the rear of the vehi’cle and support the
chassrs.3. Remove the road wheels.4. Support the axle weight with a suitable
hydraulic jack.5. Disconnect the shock absorbers.6. Disconnect the flexible brake hose at the
connection under the floor, ensuring anyexcess of fluid is stemmed.
7. Disconnect the pad wear multi-plug at thebracket mounted on the underside of thefloor. Pry the rubber grommet out of thebracket and feed the plug through the hole.
8. Disconnect the lower links at the axle.
9. Mark the differential and drive shaft driveflanges with identif ication marks to aidre-assembly. Remove the four nuts and bolts,lower the drive shaft and tie it to one side.
10. Disconnect the pivot bracket ball joint at theaxle bracket.
11. Release the bolts and remove the coil springretaining plates.
12. Lower the axle and remove the road springs.13. Withdraw the axle assembly.
Refitting
14. Position t.he axle and fit the lower links, andtighten the bolts to the specified torque (seesection 06-Torque values).
15. Reverse the removal instructions.16. Tighten the pivot bracket ball joint to axle to
the specified torque (see section 06-Torquevalues).
17. Tighten the drive shaft to differential driveflange to the specified torque (see section06-Torque values).
18. Refill the brake system and bleed as describedin Section 70.
REVISED: MARCH 90 1‘,..
OVERHAUL AXLE DIFFERENTIAL ASSEMBLY
Service Tools:
1861295 -Flange holder tool18C191 -Pinion height setting gauge186191-4 -Universal setting block18647-6 -Pinion head bearing remover/
replacerLST106 -Oil seal replacerR0262757A -Extractor for pinion bearing racesR0262757-1 -Replacer-use with R0262757AR0262757.2 -Adaptor tail bearing cap replacerR0530105 -Wrench flange and carrier bearing
nutsR0530106 -Bracket for dial gauge and
indicatorMS47 -Press
DISMANTLE
It is essential that differential components aremarked in their original positions and relative toother components so that, if refitted, their initialsetting is maintained. Note that the bearing capsmust not be interchanged.
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5.
6.
2 REVISED: MARCH 90
Remove the axle shafts then the differentialassembly from the axle.Drive out the roll pin securing the bearing nutlocking fingers to the bearing caps. Removethe locking fingers.Loosen the bearing cap bolts and mark thecaps for re-assembly.Using service tool R0530105, remove thebearing adjusting nuts.Remove the bearing cap bolts and bearingcaps.Lift out the crown wheel, (ring gear)differential unit and bearings.
7. Remove the cotter pin securing the pinionflange nut.
8. Remove the pinion flange nut using servicetool 18C1205 to restrain the flange.
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9.
10.
Withdraw the pinion complete with pinionhead bearing and outer bearing shims.Withdraw the shims.Remove the pinion flange oil seal, spacer andbearing. Discard the oil seal. ‘\
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FOE; 1989 REAR AXLE & FINAL DRlVE
11. Using service tool R0262757A, remove thepinion head bearing track and shim and driveout the outer bearing track from thedifferential housing.
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12. Remove the pinion head bearing with servicetool MS47 and adaptor 18G47-6.
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13. Remove the bolts and washers securing thecrown wheel to the differential flange.Withdraw the crown wheel.
14. Remove the differential carrier bearings.15. Remove the circlips securing the differential
cross shaft. Extract the cross shaft.16. Withdraw the differential gears and pinions.17. Thoroughly clean all components.
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INSPECTION
18. Check all bearings for wear and/or pitting.19. Check all gears for wear, scuffing, pitting and
damaged teeth.20. NOTE: The crown wheel and pinion are
supplied as a matched set, also the pinionhousing and bearing caps.
ASSEMBLE
Differential gears
21. Fit the differential gears to the differentialhousing.
22. Fit the differential cross shaft and retainingcirclips.
ST 5lOM
REVISED: DEC. 88 3‘.. . .
REAR AXLE & FINAL DRIVE 1989 “R^o”v’;;r;
23.
24.
25.
26.
Check the gear for freedom of rotation andbacklash. Nominal backlash should be present.Excessive backlash will necessitate replacementof the gears and/or the differential housing.No provision is made for backlash adjustment.Check that the serial number marked on thepinion end face matches that marked on thecrown wheel.Ensuring that the differential housing flangeand crown wheel are thoroughly clean fit thecrown wheel.Fit the carrier bearings using a suitable pressor drift and assemble the tracks traces) to thebearings.
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26
27.
28.
29.
Place the differential housing complete withcrown wheel and bear ings in the pin ionhousing.Fit the bearing caps and bolts. Do not fullytighten the bolts.Fit the bearing adjusting nuts and adjust toobtain zero end-float.
30.
31.
32.
33
Tighten the bearing cap bolts to the specifiedtorque (see section 06-Torque values).Using a dial gauge check the crown wheel forrun-out. This should not exceed 0.10 mm(0.004 in). If excessive run-out is recordedremove the crown wheel and examine crownwheel and mounting flange for burrs, grit, etc.Refit the crown wheel and recheck. Run-out,attributable to a buckled or damageddifferential housing flange can be correctedonly by replacing the differential gear housing.When sat is f ied that run-out is wi th in thespecified limits remove the differential housingfrom the pinion housing.Remove the crown wheel bolts and refit themusing Loct i te ‘Studlock’. Evenly t ighten thebolts to the speci f ied torque (see sect ion06-Torque values).
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Fit the pinion head bearing track and theor iginal sh im to the pin ion housing us ingservice tools R0262757A and R0262757-1. Ifthe original shim was damaged or mislaid usea new shim of at least 1.27 mm (0.050 in)thickness.
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35. Fit the pinion outer bearing track to the pinionhousing with service tools R0262757A andR0262757-2.
36. Fit the pinion head bearing to the pinion usingservice tool 18G47-6.
37. Enter the pinion into its location in the pinionhousing. Do not fit the shims for bearingpre-load at this stage.
38. Fit the outer bearing and spacer.39. Fit the driving flange, washer and nut.
40. Do not fit the oil seal at this stage.41. Tighten the pinion flange nut slowly until the
force required to rotate the pinion is 23 to40.25 kgf cm (20 to 35 in lb) if new beatingsare fitted. This will pre-load the bearings inorder to check the pinion height dimension.
NOTE: If using original bearings, which arebedded in, the pre-load figure is 11.5 to 17.25kgf cm (10 to 15 in lb)
Drive pinion markings
42. The markings on the end face adjacent to theserial number are of no significance duringservicing.
REVISED: DEC. 88 5 <.::
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REAR AXLE & FINAL DRIVE 1 9 8 9 KANCltROVER
43. The figure marked on the end face oppositeto the serial number indicates, in thousandthsof an inch, the deviation from nominalrequired to correctly set the pinion. A pinionmarked plus t +) must be set below nominal, aminus (-) pinion must be set above nominal.An unmarked pinion must be set at nominal.
PINION HEIGHT SHIMSr-
PART No. INCH MM
549230 ,038 0.97549232 ,040 1.02549234 ,042 1.07549236 ,044 1.12549238 .046 1.17549240 ,048 1.22549242 ,050 1.27549244 .052 1.32549246 ,054 1.37549248 .O% 1.42549250 .058 1.47549252 .060 1.52
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44. The nominal setting dimension is representedby the setting gauge block 18C191-4 which isreferenced from the pinion end face to thebottom radius of the differential bearing bore.
Drive pinion adjustment
45. Ensure that the pinion end face is free ofraised burrs around the etched markings.
46. Remove the keep disc from the magnetizedbase of dial gauge tool 18Gl91.
47. Place the dial gauge and setting block on a flatsurface and zero the dial gauge trace pin onthe setting block. Use of a surface plate isrecommended.
48. Position the dial gauge centrally on the pinionend face with the trace pin registering on thelowest point on one differential bearing bore.Note the dial gauge deviation from the zeroedsetting.
NOTE: The setting block has three settingheights as follows.
Use only the 39.50mm setting mark for thisdifferential.
49. Repeat on the other bearing bore. Addtogether the readings then halve the sum toobtain the mean reading. Note whether thetrace pin has moved up or down from thezeroed setting.
a. Where the trace pin has moved down, theamount is equivalent to the thickness of shimsthat must be removed from under the pinioninner track to bring the pinion down to thenominal position.
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6 REVISED: DEC. 88
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REAR AXLE & FINAL DRIVE 51r l
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b. Where the trace pin has moved up, theamount is equivalent to the addit ionalthickness of shims required to bring the pinionup to the nominal position.
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INCH.OOl.002.003.004.005.006.007,008,009.OlO
MM= .025= .05= .075= .I0= .125= .I5= ,175= .20= .225= .25
NOTE: DIAL INDICATOR IS METRIC! Conversionmust be made to SAE (INCH) UNITS whenperforming measurements and selecting shims.
50. Before adjusting the shim thickness, check thepinion face marking and if it has a plus (+)figure, subtract that amount in thousandths ofa n i n c h f r o m t h e s h i m t h i c k n e s s f i g u r eobtained in the previous item.
51. Al ternat ively, i f the pinion has a minus (-)figure, add the amount to the shim thicknessfigure. Adjust the shim thickness under thepinion head bearing track as necessary.
52. Recheck the pinion height sett ing. I f thesetting is correct, the mean reading on the dialgauge will agree with the figure marked on thepinion end face. For example, with an endface marking of +3, the dial gauge readingshould indicate that the pinion is + 0.003 in.
Bearing pre-load adjustment
53 . Remove the p in ion f lange , p in ion , ou te rbearing and spacer.
54. Slide new shims, of the same thickness as theoriginals (bearing pre-load) into position onthe pinion shaft . If the or ig inal sh im wasdamaged or mislaid use a new shim of at least4.06 mm (0.160 in) thickness.
55. Enter the pinion in its location in the pinionhousing and fit the outer bearing and spacer.
56. Fit the driving flange, washer and nut.
57. Do not fit the oil seal at this stage.58. Tighten the pinion flange nut to the specified
torque (see section 06-Torque values). Theforce required to rotate the pinion shaftshould be within 23 to 40.25 kgf cm (20 to 35in lb) using new bearings, when initial inertiahas been overcome. Change the bear ingpre-load shim as necessary to obtain thisrequirement. A th icke r sh im w i l l reducepre-load; a thinner shim will increase pre-load.
NOTE: If using original bearings, which arebedded in, the pre-load figure is 11.5 to 17.25kgf cm (10 to 15 in lb)
59. Remove the pinion flange.
PINION PRELOAD SHIMS
PART No. INCH M M
FRC1193 .060 I.52FRCl195 ,062 1.57FRC1197 ,064 I.63FRC1199 .066 1.68FRCI 201 .068 I.73FRCl203 .070 1.78539718 .072 1.83539720 .074 1.88539722 .076 1.93539724 ,080 2.03
Fitting Pinion Oil Seal:. .
CAUTION: Before fitting the new seal to thedifferential, examine the seal to ensure that it isclean, undamaged and that the garter spring isproperly located. A small scratch on the seal lipscould impair its efficiency.
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REVISED: JULY 88 7
REAR AXLE & FINAL DRIVE 1 9 8 7 lcANGEROVER
60. Coat the outer diameter of the new seal widthwith an all purpose grease and fit the seal, lipside leading squarely on the pinion nosehousing and drive the seal into position flushwith the end face of the housing using sealreplacing tool LST106.
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61. Lightly lubricate the seal lips with arecommended oil. Fit the distance piece andflange and secure with washer and nut.Tighten the nut to the specified torque and fita new cot ter p in (see sect ion 06-Torquevalues).
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CROWN WHEEL/PINION BACKIASHADJUSTMENT
62. Place the differential housing in the pinionhousing.
63. Fit the bearing caps and bolts. Do not fullytighten the bolts.
64. Fit the bearing adjusting nuts.
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65.
66.
Push the crown wheel into mesh with thepinion, loosening the left hand bearingadjuster nut, using service tool 530105.T i g h t e n t h e r i g h t h a n d n u t u n t i l c r o w nwheel/pinion backlash is just removed.
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67. Tighten the left hand nut slowly unti l i tcontacts the bearing. Continue turning the lefthand nut until a backlash of 0.10 to 0.17 mm(0 004 to 0.007 in) is achieved. DO NOTslacken the r ight hand nut at any t ime,othmwse the bearing preload will be affected.
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CAUTION should also be taken when performingBacklash Setup i.e. convert metric readings toinches.
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8 REVISED: JULY 88
REAR AXLE & FINAL DRIVE:.
68. Fit the locking fingers and roll pins. Ifnecessary, tighten the adjustment nuts slightlyto align the locking finger with a slot.
69. Evenly tighten the bearing cap bolts to thespecified torque (see section 06-Torquevalues).
70. Recheck crown wheel/pinion backlash.71. Lubricate the bearings and gears.
DATA
Pinion bearing pre-load:(new bearings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 to 40.25 kgf cm (20 to 35 in lb)(bearings bedded in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.5 to 17.25 kgf cm (IO to 15 in lb)
Crown wheel run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in)Crown wheel/pinion backlash . . . . . . . . . . . . I ,................. 0.10 to 0.17 mm (0.004 to 0.007 in)
REAR DISCS 7. Fit the rear hub assembly.
Remove and refit Disc Reclamation
Removing
1. Remove the rear hub assembly.2. Remove the rear disc fixing bolts.3. Tap off the disc from the rear hub.
Check the disc thickness marked on the discboss-this dimension may be reduced to a minimumthickness of 13 mm (0.510 in) front and 12 mm(0.460 in) rear, by machining an equal amount offeach face.
Refitting REMOVE AND OVERHAUL REAR HUBS
4. Locate the disc onto the rear hub. Service tools:
(. :..>.5. Fit the disc fixing bolts. See Section 06 for
tightening torques.6. Using a dial indicator, check the total disc run
out, this must not exceed 0.15 mm (0.006 in).If necessary reposition the disc.
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Oil seal replacer -LST550-5Drift for above tool -MS550 or 186134Hub nut wrench -606435
Remove
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1. Jack-up the vehicle, lower on to axle standsand remove the road wheels.
2. Release the brake hose from the axle, casingclips and remove the brake caliper retainingbolts and secure the assembly to one side.Tal e care not to kink the brake hose.Remove the five bolts securing the axle shaftto the hub and withdraw the shaft.
REVISED: MARCH 90 9,:;
REAR AXLE & FINAL DRIVE 1987 kANbcROVER
4. Bend back the lock tab and remove the outernut using box wrench 606435 and remove -remove the lock washer. Likewise remove theinner nut.
5. Remove the seal track spacer.6. Withdraw the hub complete with bearing oil
seals and brake disc.7. Remove the inner and outer oil seals.8. Remove the inner and outer bearing cones
(races).9. Drive-out the inner and outer bearing cups.
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10. Degrease and examine the hub and brake discand if necessary replace both or whicheverpart is unserviceable. The disc is attached tothe hub with five bolts. Mark the relationshipof the hub to the disc if the original parts areto be re-assembled.
1 I. Examine the stub axle and in particular checkthat the inner seal track is smooth and freefrom blemishes.
12. If necessary remove the six retaining bolts andremove the stub axle complete with themudshield and joint washer.
Assemble
13. Using a new joint washer fit the stub axle andmud shield. Coat the threads of the retainingbolts with Loctite 270 and tighten evenly tothe correct torque (see section OC-Torquevalues).
14. Fit the new inner and outer bearing cups tothe hub, using a suitable drift or commercial --bearing race driving tool.
10 REVISED: MARCH 90
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REAR AXLE & FINAL DRIVE [ii 1
15. Fit the new inner bearing cone and pack withone of the recommended hub greases.
Fitting new oil seal-inner
16. Clean the hub oil seal housing and ensure thatthe seal locating surface is smooth and thechamfer on the leading edge is also smoothand free from burrs.
17. Examine the new seal and ensure that it isclean and undamaged and that the garterspring is properly located. Even a small scratchon the seal lip could impair its efficiency.
18. Although the new seal is already pre-greasedby the manufacturer, apply one of therecommended hub bearing greases to theoutside diameter of the seal before fitting,taking care not to damage the lip.
19. Place the seal, lip side leading, squarely on thehub and using the 76 mm end of seal replacertool LSTSSO-5 and drift 550 or 18C134, drivethe seal into position, flush with the end faceof the hub.
Fitting outer oil seal
20. Fit the new outer bearing cone and pack withone of the recommended hub greases. Carryout instructions 16 to 18.
21. Place the seal, lip side leading, squarely on thehub and using the 72 mm end of seal replacertool LSTSSO-5 and drift 550 or l8Gl34, drivethe seal into position to the depth determinedby the tool.
22. Coat the lips of both seals with one of therecommended greases. This is important sincea dry seal can be destroyed during the firstfew revolutions of the hub.
Fitting hub to stub axle
23.
24.
25.
26.
Select a new seal track spacer and check thatthe outer diameter is smooth and free fromblemishes and that there are no burrs on thechamfered leading edge.Taking care not to damage the seal lips fit thehub assembly to the stub axle. Do not allowthe weight of the hub to rest even temporarilyon the outer seal otherwise damage anddistortion could occur. Therefore hold the hubclear of the stub axle until the seal trackspacer is fitted.Carefully fit the seal track spacer, seal lipleading.
NOTE: Instruction 26 is applicable to hubsthat have been fitted with new componentsthroughout. If original components arebeing refitted instruction 27 must befollowed using the adjustment nut toachieve the required end-float.
Fit the hub inner nut and using wrench 606435tighten the adjusting nut while slowlyrevolving the hub until all end-float isremoved, then back-off the nut approximatelyhalf a turn and retighten the nut to 13-15 in lbwhich will automatically allow for compressionof the rubber on thP new seal track spacergiving the required hub end-float of 0.013 to0.10 mm (0.0005 to 0.004 in).
Continued
REVISED: APR. 88 ‘11
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r-t51 REAR AXLE & FINAL DRIVE 1987 KANClcROVER
27. If the rubber on the seal track spacer hasp r e v i o u s l y b e e n compresssed t h e h u bend-float can be checked by mounting a dialindicator and bracket on the hub so that thetrace pin rests in a preloaded condition on thenut. Rotate the hub to settle the bearings andcheck the end-float by pushing and pulling thehub. End-float must fall within the limits givenin the previous instruction.
28. Fit a new lock washer and locknut. Restrainingthe inner adjustment nut, tighten the outerlock nut to 70 to 80 ft lb (95 to 108 Nm).
29. If original components have been refittedrotate the hub several trmes to settle thebearings then recheck the end-float, refer toprevious note and instruction 27.
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33. Fit the road wheels, jack-up the vehicle,remove the axle stands, lower the vehicle tothe ground and tighten the road wheel nutsevenly to the correct torque.
30. Bend one segment of the lock washer overthe adjusting nut and another, diametricallyopposite, over the locknut taking care not todamage the outer seal.
31. Using a new joint washer, fit the hub driving’shaft and evenly tighten the retaining bolts tothe correct torque (see section 06-Torquevalues).
32. Fit the brake caliper and secure with theretaining bolts and tighten to the correcttorque (see section 06-Torque values). Securethe brake pipes to the axle casing.
12 REVISED: APR. 88
’ :i. REAR AXLE & FINAL DRIVE
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KEY TO REAR HUB COMPONENTS..; :,: .I,
:,,_ I,*.A’.....- 1. Rear axle shaft 11. Inner bearing cup2. joint washer 12. Inner bearing cone3. locknut 13. Inner oil seal4. Lock washer
v14. Mudshield
5. Adjusting nut 15. Stub axle6. Seal track spacer 16. Stub axle joint washer7. Outer oil seal 17. Brake disc8. Outer bearing cone9. Outer bearing cup
10. Hub
REVISED: APR. 88.
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REAR AXLE & FINAL DRIVE1 9 9 0 ;;g$;
REAR HUB ASSEMBLY ON VEHICLES FIT-TED WITHANTI-LOCK BRAKES (ABS)
REMOVE, OVERHAUL AND REFIT
Service tools:Hub oil seal replacer LST 137.Drift 18C 134.Dial gauge bracket RO 530106.
Remove
1.
2.
Slacken the rear wheel nuts, jack up thevehicle, lower onto axle stands and removethe road wheel.Release the brake pipe from the axle, casingclips and remove the brake caliper retainingbolts then secure the assembly to one side.
WARNING: Take care not to kink the brakepipe.
3. Lever off the dust cap.4. Remove the circlip from the rear axle shaft.
KEY TO REAR HUB COMPONENTS
1.2.3.4.5.6.7.8.9.10.11.12.
Dust cap.Circlip.Sensor ring retaining nut.Drive member.Drive member joint washer.Drive member retaining bolt (five off).Lock nut.Lock washer.Hub adjusting nut.
Keyed washer.Outer bearing.H u b .
13. Inner bearing.14. Grease seal.15. Brake disc.16. Disc retaining bolt (five off).17. Sensor ring.
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5. Remove the five bolts and withdraw thedriving member and joint washer.
6. Bend back the lock washer tab.7. Remove the locknut and tab washer.8. Remove the hub adjusting nut.9. Remove the keyed washer.
10. Withdraw the hub and brake disc assemblycomplete with bearings.
11, Remove the outer bearing.12. Remove the five nyloc nuts and withdraw the
sensor ring.13. Mark, for reassembly, the relationship between
the hub and brake disc, if original hub is to berefitted.
14. Remove the five bolts and separate the hubfrom the brake disc.
WARNING: A maximum of two road wheelretaining studs can be renewed. Shouldm o r e s t u d s b e u n s e r v i c e a b l e a new hubwith studs must be obtained.
15. Drift out the grease seal and inner bearingfrom the hub and discard the seal.
16. Drift out the inner and outer bearing tracks.
ADDITION: SEPT. 89
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R”^o”;; 1 9 9 0 REAR AXLE & FINAL DRIVE
Refi t 20.
17. Clean and degrease the hub and drift in theinner and outer bearing tracks.
18. Pack the hub inner bearing with arecommended grease and fit to the hub.
19. With the lip side leading fit a new seal to thehub using special tool LST 137 seal replacerand drift 18G 134. Drive in the seal so that itis flush with the rear face of the hub. Applygrease between the seal lips.
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21.
22.
23.
24.25.26.
27.
Assemble the brake disc to the hub, lining upto the marks made during dismantling.Applying Loctite 270, fit and tighten the fiveretaining bolts to the correct torque.I f necessary renew any sensor r ing s tudsapplying Loctite 270 where the stud screwsinto the sensor ring. Fit the sensor ring usingnew nyloc nuts, ensuring it is correctly fittedto avoid tooth run out.Grease as in instruction 18 and fit the outerbearing to the hub.Clean the stub axle and rear axle shaft andretract the ABS sensor slightly from sensorsleeve.Fit the hub assembly to the stub axle.Fit the keyed washer.Fit the hub adjusting nut and tighten by handwhilst rotating the hub until all end-play istaken up.Mount a dial gauge using bracket RO 530106and rest the stylus in a loaded condition onthe adjusting nut.
RR2772M RO 530106
28 Gcken off the adjusting nut until a end-play(11 0 013 to 0,05 mm (0.0005 to 0.002 in) is(~l~ralned.
2’1 I II a new keyed lock tab washer.(11 I I I and t ighten the hub adjust ing nut and
I(‘( heel, the end-play before bending the locktdb over.
31 Fir a new joint washer to the driving memberand frt the member to the hub and securewith the five bolts tightening evenly to thecorrect torque.
ADDITION: SEPT. 89 15
REAR AXLE & FINAL DRIVE1990 R”d;;i
32. Fit the circlip to the rear axle shaft, ensuringthat it locates in the groove.
33. Fit the dust cap.34. Fit the brake caliper and tighten the two bolts
!o the correct torque. Secure the brake pipesto the axle casing.
35. Set the ABS brake sensor. Push the sensorthrough the bush until it touches the sensorring. The sensor sets to its correct positionwhen the hub is rotated.
36. Fit the road wheel, remove the axle stands andfinally tighten the road wheel nuts.
37. Operate the footbrake several times to locatethe brake pads before taking the vehicle onthe road.
REAR STUB AXLE ON VEHICLES FlITED WITH ABS
Special tools:Oil seal replacer LST 138.Drift 18G 134.
KEY TO STUB AXLE COMPONENTS
1. Rear axle shaft.2. Stub axle to axle casing bolt.3. Mudshield.4. Stub axle.5. Stub axle joint washer.6. Axle case.7. Sensor bush sleeve.
REMOVE, OVERHAUL AND REFIT
Remove rear stub axle, axle shaft
1. Remove the hub complete as described in theoperation to overhaul the hub assemblyinstructions 1 to 10.
2. Remove the six bolts retaining the stub axle tothe axle casing.
3. Remove the mud shield.4. Remove the stub axle and joint washer.5. Pull-OUI the rear axle shaft f rom the axle
casing.
Refit
6. Using a new joint washer fit, the stub axle andmudshield with the retaining bolts, to the axlecasing tightening evenly to the correct torque.
7. Carefully fit the rear axle shaft to avoiddamaging the stub axle seal.
8. Refit the hub assembly complete as describedin the operation to refit the hub assemblyinstructions 23 to 37.
Renew rear stub axle oil seal
1. Remove and discard the oil seal. Lubricate theseal and lip with EP90 oil and using specialtool LST 138 fit a new oil seal lipside trailingso that the seal is flush with the rear face ofthe stub axle.
RR2759Mkd
ADDITION: SEPT. 89
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REAR AXLE & FINAL DRIVE
REAR DISCS ON VEHICLES FllTED WITH ABS
REMOVE, REFIT AND RECLAIM
Removing
1. Remove the rear hub assembly.2. Remove the five nyloc nuts.3. Remove the sensor ring.4. Remove the five hub to disc retaining bolts.5. Tap off the disc from the hub.
Refitting
6. Locate the disc onto the hub.7 . Apply loc t i te 270 and f i t t he hub to d i sc
retaining bolts. Tighten to the correct torque.8. Using new nyloc nuts fit the sensor ring.
9. Using a dial indicator, check the total discrunout, this must not exceed 0,15 mm (0.006in). If necessary reposition the disc.
10. Fit the hub assembly.
Disc Reclamation
Check the disc thickness. This dimension maybe reduced to a minimum thickness of 12 mm(0.460 in). Equal amounts must be machinedoff both sides of the disc.
ADDITION: SEPT. 89 17
roFf; 1987 FRONT AXLE & FINAL DRIVE
FRONT AXLE ASSEMBLY
Remove and refit
Removing
WARNING: The removal of the axle from thevehicle will require the assistance of two furtherpersonnel to steady the axle when lowering fromthe vehicle.
Jack up the front of the vehicle and supportthe chassis frame.Remove the front road wheels.Suppor t t he ax le we igh t w i th a su i tab lehydraulic jack.Remove the nuts securing the radius arms tothe chassis frame side members.
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9.
IO.
Disconnect the steering damper at the tie rodand using a suitable extractor remove the tierod ends from the swivel pin housing arm.Remove the four nuts and bolts securing theradius arms to the axle bracket.Lower the radius arms and withdraw themfrom the chassis side members.Remove the two bolts from the top of theswivel pin housings securing the brake hosebrackets. Remove the brackets and refit thebolts to prevent oil leakage.Disconnect the brake pad wear electricalmulti-plug at the rear of the caliper (whereapplicable).Remove the bolts securing the brake calipersand tie the calipers to one side.
153
6 ll&\ !. E
iRR742M
11.
12.
13.
Remove the nuts and washers securing theshock absorbers to the axle.Using a suitable extractor disconnect the draglink from the swivel pin housing arm.Remove the two nuts and bolts securing thepanhard rod to the axle bracket and lift therod clear of the axle.
14. Mark the differential and drive shaft flangeswith identification marks to aid re-assembly.Remove the four nuts and bolts, tie the driveshaft to one side.
15. Carefully lower the axle assembly and removethe road springs.
16. Withdraw the axle assembly.
Refitting
17.
18.19.
20.
21.
22.
23.
Position the axle under the vehicle, supportingthe left hand side of the axle.Reverse the removal instructions.Tighten the drive shaft to differential bolts tothe specified torque (see section 06-Torquevalues).Tighten the panhard rod to axle bracket to thespecified t o r q u e ( s e e s e c t i o n 06-Torquevalues).T i g h t e n t h e d r a g l i n k t o h u b a r m t o t h es p e c i f i e d t o r q u e ( s e e s e c t i o n OC-Torquevalues).Tighten the upper swivel pin retaining bolts tothe specified torque (see section 06-Torquevalues).Tighten the radius arms to axle bolts to thespecified t o r q u e (see s e c t i o n 06-Torquevalues).
REVISED: JULY 88
,
2 4 . T i g h t e n t h e r a d i u s a r m s t o c h a s s i s s i d e FRONT DISCS:,.
:member nuts to the specified torque (seesection 06-Torque values).
,.25. Tighten the track rod end to the specified
torque and fit a NEW cotter pin (see section06-Torque values).
FRONT DIFFERENTIAL-OVERHAUL
The front and rear differentials fitted to Range Roverare the same type. When overhauling the frontdifferential refer to the rear differential overhaulprocedure in Section 51 of this manual.
Remove and refit
Removing
1. Remove the front hub assembly.2. Remove the front disc fixing bolts.3. Tap the disc off the front hub.
1 3
Refitting
4. Locate the disc onro the front hub.5. Fit the disc fixing bolts. See Section 06 for
tightening torques.6. Using a dial indicator, check the total disc
run-out, this must not exceed 0.15 mm (0.006in). If necessary, reposition the disc.
7. Fit the front hub assembly.
.:,(.‘.. ., 2
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.i
REVISED: JULY 88
I
..-
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‘_
PO;;; 1987 FRONT AXLE & FINAL DRIVE l-l54
REMOVE AND OVERHAUL FRONT HUB
Service tools:Oil seal replacer ................................................. LSTSSO-5Drift for above tool ............................................. MS550 or 18Gl34Hub nut wrench .................................................. 606435
KEY TO FRONT HUB COMPONENTS
1.2.3.4.5.6.7.8.9.
10.11.12.
I’
Hub driving shaftGasketLocknutLock washerAdjusting nutSeal track spacerOuter oil seal
13. Inner oil seal14. Mudshield15. Stub axle16. Stub axle joint washer17. Brake disc
Remove
.i
1. lack-up the vehicle, lower onto axle standsand remove the road wheels.
2. Remove the swivel housing top bolt to releasethe brake hose bracket.
3. Remove the brake caliper retaining bolts andrelease the assembly from the brake disc andsecure to one side.
4. Remove the f ive bolts retain ing the hubdriving shaft and withdraw the shaft from thehub.
5. Bend back the lock-tab and remove the outernut using wrench 606435 and remove the lockwasher. Similarly, remove the inner nut.
6. Remove the seal track spacer.7. Withdraw the hub complete with bearings, oil
seals and brake disc.8. Remove the inner and outer oil seals.9. Remove the inner and outer bearing cones.
REVISED: FEB. 87 3
r54 FRONT AXLE & FINAL DRIVE 1987 KANCIEROVER
10. Drive out the inner and outer bearing cups.
11. Degrease and examine the hub and brake discand fit new components where necessary. Thebrake disc is attached to the hub by five bolts.Mark relation of hub to disc as necessary
1’ Clean and examine the stub axle and in6.particular check that the inner seal trackdiameter is smooth and free from blemishes.
4 REVISED: FEB. 87
13. If necessary remove the retaining bolts andwithdraw the stub axle. Complete with themudshield and joint washer.
..-,’
Assemble
14. Using a new joint washer fit the stub axle andmudshield. Coat the threads of the retainingbolts with Loctite 270 and tighten evenly tothe specified torque (see section 06-Torquevalues).
15. Fit the new inner and outer bearing cups tothe hub, use a suitable brass drift orcommercral race driver to prevent damage tothe bearing cups., I
RR070M .- \.
16. Fit the new inner bearing cone and pack withone of the recommended i xub greases.
Fitting new oil seal-inner
17. Clean the hub oil seal housing and ensure thatthe seal locating surface is smooth and thechamfer on the leading edge is also smoothand free from burrs.
18. Examine the new seal and ensure that it isclean and undamaged and that the garterspring is properly located. Even a small scratchon the seal lip could impair its efficiency.
; ;
.-
,. ’ .
R”%; 1987 FRONT AXLE & FINAL DRIVE [!$i 1
19.
20.
Although the new seal is already pre-greasedby the manufac turer , app ly one o f therecommended hub bearing greases to theoutside diameter of the seal before fitting.Place the seal, lip side leading, squarely on thehub and using the 76 mm end of seal replacertool LST550-5 and drift 550 or 18Cl34, drivethe seal into position flush with the end faceof the hub.
Fitting outer oil seal
21.
22.23.
24.
Fit the new outer bearing cone and pack withone of the recommended hub greases.Carry out instructions 17 to 19.Place the seal, lip side leading, squarely on thehub and using the 72 mm end of seal replacertool LST550-5 and drift 550 or 186134, drivethe seal into position to the depth determinedby the tool.Coat the lips of both seals with one of therecommended greases. This is important sincea dry seal can be destroyed during the firstfew revolutions of the hub.
Fitting hub to stub axle
25. Select a new seal track spacer and check thatthe outer diameter is smooth and free fromblemishes and that there are no burrs on thechamfered leading edge.
26. Taking care not to damage the seal lips fit thehub assembly to the stub axle. Do not allowthe weight of the hub to rest even temporarilyon the outer seal otherwise damage anddistortion could occur. Therefore hold the hubclear of the stub axle until the seal trackspacer is fitted.
27.
28.
29.
Carefully fit the seal track spacer, chamferedside leading.
NOTE: Instruction 28 is applicable to hubsthat have been fitted with new componentsthroughout . I f o r ig ina l components a rebeing r e f i t t e d i n s t r u c t i o n 2 9 m u s t b ef o l l o w e d u s i n g t h e a d j u s t m e n t n u t t oachieve the required end-float.
Fit the hub inner nut and using wrench 606435tighten the adjusting nut while slowlyrevolving the hub until all end-float is removedmen back-off the nut approximately half a turnand retighten the nut to 13-15 in lb which willautomatically allow for compression of therubber on the new seal track spacer giving therequired hub end-float of 0.013 to 0.10 mm(0.0005 to 0.004 in ).If the rubber on the seal track spacer ‘haspreviously been compressed the hub end-floatcan be checked by mouting a dial indicatorand bracket on the hub so that the trace pinrests in a preloaded condition on the nut.Rotate the hub to settle the bearings andcheck the end-float by pushing and pulling thehub. End-float must fall within the limits givenin the previous instruction.
Continued-’
REVISED: APR. 88 5‘.
:
.’
: ;’
1987 KANbtROVER
30. Fit a new lock washer and iocknut. Restrainingthe inner adjustment nut, tighten the outerlock nut to 70 to 80 ft lb (95 to 108 Nm).
31. If original components have been refittedrotate the hub several times to settle thebearings then recheck the end-float, refer toprevious instruction 29.
32. Bend one segment of the lock washer overthe adjusting nut and another, diametricallyopposite, over the locknut.
32‘\ ‘\
I31
AR97684
33. Using a new gasket, fit the hub driving shaftand evenly tighten the retaining bolts to thespecified t o r q u e ( s e e s e c t i o n 06-Torquevalues).
34. Fit the brake caliper and secure with theretaining bolts and tighten to the specifiedtorque (see section 06-Torque vaiues).
35. Fit the swivel housing top bolt and brake hosebracket and tighten to the specified torque(see section 06-Torque values).
36. Fit the road wheels, jack-up the vehicle,remove the axle stands, lower the vehicle tothe ground and tighten the road wheel nutsevenly to the specified torque (see section06-Torque values).
OVERHAUL STUB AXLE, AXLE SHAFT, CONSTANTVELOCITY JOINT AND SWIVEL PIN ASSEMBLY
I
Removing hub assembly, stub axle, constantvelocity joint and axle shaft.
Remove the hub complete as described in thehub assembly overhaul operation instructions1 to 7.Drain the swivel pin housing and refit plug.Remove the six bolts retaining the stub axle tothe swivel pin housing.Remove the mud shield, stub axle and jointwasher.Remove the brake disc shield secured by onenut and bolt at the bottom front, and onebolt, behind the shield, in the swivel pinhousing.
6.’
REVISED: APR. 88
6. Disconnect the tie-rod end ball joint from theswivel pin housing.
‘.-.:‘!
7. Disconnect the drag-link ball joint.
‘.I
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Foe; 1987FRONT AXLE & FINAL DRIVE
8. Remove the constant velocity joint from theaxle shaft.
RR207SM
9. Remove the spacer from the axle shaft andthen the axle shaft from the axle tube.
10. Remove the phosphor bronze bush from theaxle shaft.
Dismantling the constant velocity joint
11.
12.
Mark -the relative positions of the constantvelocity joint, inner and outer race and thecage to ensure correct re-assembly.Tilt and swivel the cage and inner race toremove the ball bearings,
Continued
RR2076M \
REVISED: JULY 88
FRONT AXLE & FINAL DRIVE 1987 KANbtROVER
RR207BM
13. Swivel the cage into line with the axis of thejoint until the two opposite windows coincidewith the two lands of the joint housing.
14. Withdraw the cage.15. Turn the inner track at right angles to the cage
with two of the lands opposi te the cageopenings, and withdraw the inner race.
16. Examine all components for general conditionand examine the inner and outer track, cageballs and bearing surfaces of the constant
17.
velocity joint for damage and excessive wear.Maximum acceptable end- f loa t on theassembled joint 0.64mm (0.025 in).To assemble the constant velocity joint reversethe dismantling instructions and lubricate witha recommended oil, ensuring that the innerand outer race marks are al igned dur ingassembly.
Overhaul of stub axle
18.
19.
20.
Remove the phosphor bronze bush using asuitable hammer and drift.Clean and examine the stub axle. In particularcheck that the inner seal track diameter issmooth and free from blemishes.Using a suitable block, press or drive-in a newbush up to the shoulder of the stub axle.
. .
Removing the swivel pin housing assembly
21.
22.
23.24.
25.
26.
27.
28.
Remove the seven bolts securing the swivelpin housing oil seal, retaining plate and jointwasher. Release the assembly from the swivelpin housing.
N O T E : W h i l e t h e j o i n t w a s h e r c a n b eremoved at this stage, the oil seal andretaining plate must remain until the swivelbearing housing is removed.
Remove the two bolts, retaining the brake discshield bracket, and lower swivel pin to thehousing.Remove the brake disc shield bracket.Tapping the small protruding lug remove thelower swivel pin and joint washer.Remove the two bolts retaining the brakehose bracket and top swivel pin.Remove the brake hose bracket, top swivel pinand shims.Remove the swivel pin housing while retrievingthe lower and upper tapered roller bearings.If the swivel pin housing is to be replaced,r e m o v e t h e d r a i n a n d l e v e l p l u g s a n dlock-stop bolt and nut.
,_. . . .. ,
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8 REVISED: JULY 88:
.‘.: .;,
;;%; 1987 FRONT AXLE & FINAL DRIVE 54r - l
Overhaul of swivel bearing housing
29. Using a suitable drift ease the lower bearingtrack out of the swivel bearing housing.
NOTE: Use the upper bearing opening forthe drift to gain access to the lower bearingtrack.
6
11IrRRBBOM
KEY TO SWIVEL ASSEMBLY
1.2.3.4.5.6.7.8.9.
10.11.12.
Swivel pin housingTop swivel pin and brake hose bracketUpper and lower swivel pin bearingsShimSwivel pin housing-oil seal plate and washerOil sealJoint washerSwivel bearing housingjoint washerLower swivel pinBrake disc mudshield bracketSwivel bearing housing inner oil seal
30.
31.
32.
33.
34.35.36.
37.
Remove the seven bolts retaining the swivelbearing housing to the axle case.Pry out the oil seal from the back of thehousing also remove the joint washer anddiscard both.Bolt the swivel bearing housing onto the axlecase with the upper bearing track located atthe bottom.Drive out the top bearing track from theswivel bearing housing.
NOTE: Use the lower bearing opening forthe drift to gain access to the upper bearingtrack.
Remove the bolts from the housing.If worn, pitted or damaged, fit a new housing.Using a suitable toolseat the upper and lowerbearing tracks into the swivel bearing housing.
NOTE: Ensure the bearing tracks are fittedsquare or damage could occur.
With the seal lips trailing press the axle shaftoil seal into the rear of the housing, alsogrease the lips.
Reassembling the swivel pin housing assembly
38.
39.
40.
41.
42.
Coat the swivel bearing housing to axle casing.bolts with Loctite 270.Coat both sides of the joint washer with asealing compound and place in position onthe swivel bearing housing to axle mating face.Place the swivel pin housing cover plate jointwasher and oil seal over the axle flange readyfor assembly.Fit and secure the swivel bearing housing tothe axle flange with the seven bolts tighteningevenly to the specified torque (see section06-Torque values).Grease and fit the upper and lower swivel pintaper roller bearings to the swivel bearinghousing.
Continued
. . _-.
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REVISED: JULY 88 9 ,.,’. .
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FRONT AXLE & FINAL DRIVE 1987 nANb=ROVER
43. Place the swivel pin housing in position overthe swivel bearing housing.
44. Coat a jo int washer on both s ides wi th asealing compound and place in position onthe lower swivel pin.
45. Fit the lower swivel pin with the lug outboardto the swivel pin housing. (DO NOT tightenthe bolts at this stage).
46. Fit the top swivel pin with existing shims andb r a k e h o s e b r a c ke t o n t o t h e s w i v e l p i nhousing, secur ing wi th the two bol ts andlocking washers. (DO NOT tighten the boltsat this stage).
4i. Coat the threads of the two lower swivel pmbolts with Loctite 270.
48. Fit the brake disc shield bracket and securewith the two bolts to* the specified torque (seeSection 06) and bend over the lock tabs of themudshield bracket.
49 . T igh ten the top sw ive l p in bo l t s to thespec i f ied to rque ( see Sec t ion 06.Torquevalues).
RR982M - 1
50. To check the top swivel pin pre-load, attach aspring balance to the track-rod and ball jointbore and pull the balance to determine theeffort required to turn the swivel pin housing.The resistance, once the initial inertia has beenovercome, should be 1.16 to 1.46 kg (2.6 to3.2 lb). If necessary, adjust by removing oradding shims to the top swivel pin as required.When the correct setting has been achievedundo the bolts, coat the threads with Loctite270 and retighten the bolts to the specifiedtorque (see Section 06-Torque values), andbend over the tabs of the locking washer.
62. Place the mudshield onto the stub axle and>ecurc to the swivel pin housing with the sixt)ol~~ using Loctite 270. Evenly tighten to the51~~ Itled t o r q u e ( s e e S e c t i o n OC-Torque1 dlIW\ j
63 10 ’ 1 )mplete the reassembly see instructions: I 111 1t1 covering front hub overhaul.
NOTE: New hub seals should be used onreassembly. .i
64. CherL that the swivel pin housing drain plug istlghrl\ tltted and remove the filler/level plug.
65. lnlect approximately 0.35 litres (0.6 pints) ofrecommended oil or until the oil reaches thefiller level hole. Fit and tighten the plug andwipe away any surplus oil.
66. Set the steering lock-stop bolts to provide a : .“;minimum clearance of 20 mm (0.787 in) . . .’between the tyre wall and radius arm. Tightenthe locknut.
10 REVISED: JULY 88
:.‘.
51. Liberally apply (but do not pack) 2.5 to 4.Og of .-!!
recommended grease between the lips of theswivel oil seal.
52. Secure the oil seal, joint washer and coverplate with the seven bolts and spring washersto the specified torque (see Section 06-Torquevalues).
53. Fit the tie-rod and drag link and secure withnew cotter pins, where applicable. Tighten tothe specified tourque. (See Section 06 TorqueValues)
54. Fit the brake disc shield.55. Loosely fit the lock stop bolt and nut for later
adjustment.
Constant velocity, stub axle and axle shaftreassembly
56. Fit a new phosphor bronze bush onto the axleshaft. 1
57. Place axle shaft into axle tube, ensuring thesplines are engaged push the shaft home.
CAUTION: When inserting the axle shaft careshould be taken not to damage the oil seal.
58.
59.60.
61.
Fit the constant velocity bearing journal intothe phosphor bronze bush at the rear of thestub axle.Fit the spacer onto the axle shaft.P lace the joint washer in posi t ion on theswivel pin housing to stub axle mating surface.Fit the stub axle with the machined flat on thesplines in the 12 o’clock position, ensuringthat the constant velocity bearing journalengages fully into the phosphor bronze bush.
CAUTION: Damage to this bush can occur if thisprecaution is not observed.
.,,i
R”;g 1990 FRONT AXLE & FINAL DRIVE hii
FRONT HUB ASSEMBLY ON VEHICLES FllTEDWITH ANTI-LOCK BRAKES (ABS)
1.. .:.-1.1 ., : .,:.t:Service tools:Hub oil seal replacer LST 137.Drift 18C 134.Dial gauge bracket RO 530106.
REMOVE, OVERHAUL AND REFIT
Remove
1. Slacken the front wheel nuts, jack up thevehicle and lower onto axle stands andremove the road wheel.
2. Remove the brake cal iper . See BRAKESsection.
3. Lever off the dust cap.4. Remove the circlip and drive shaft shim from
the drive shaft.5. Remove the five bolts and withdraw the
driving member and joint washer.
KEY TO HUB ASSEMBLY
1. Dust cap.2. Drive shaft circlip.3. Drive shaft shim.
3 . 4. Drive member.5. Drive member joint washer.6. D&e member retaining bolt (five off)7. Lock nut.8. Lock washer.9. Hub adjusting nut.
10. Keyed washer.11. Outer bearing.12. Hub.13. Inner bearing.14. Grease seal.15. Brake disc (vented).16. Disc retaining bolt (five off).
6.7.8.9.
10.
11.12.
13.
14.
15.
Bend back the lock washer tab.Remove the locknut and tab washer.Remove the hub adjusting nut.Remove the keyed washer.Withdraw the hub and brake disc assemblycomplete with bearings.Remove the outer bearing.Mark, for reassembly, the relationship betweenthe hub and brake disc, if original hub is to berefitted.Remove the five bolts and separate the hubfrom the brake disc.
W A R N I N G: A maximum of two road wheelretaining studs can be renewed. Shouldmore studs be unserviceable a new hubwith studs must be obtained.
Drift out the grease seal and inner bearingfrom the hub and discard the seal.Drift out the inner and outer bearing tracks.
ADDITION: SEPT. 89 11‘.
1990 KANGeROVER
Refit
16. Clean and degrease the hub and drift in theinner and outer bearing tracks.
RR2767M
17.
18.
Pack the hub inner bearing with arecommended grease and fit to the hub.With the lip side leading fit a new seal to thehub using special tool LST 137 seal replacerand drift 18C 134. Drive in the seal so that itis flush with the rear face of the hub. Applygrease between the seal lips.
18G.134
LST
12 ADDITION: SEPT. 89
19.
20.
21.
22.23.
24.
Assemble the brake disc to the hub, lining upto the marks made dur ing d ismant l ing .Applying Loctite 270, fit and tighten the fiveretaining bolts to the correct torque.Grease as in instruction 17 and fit the outerbearing to the hub.Clean the stub axle and drive shaft and fit thehub assembly to the axle.Fit the keyed washer.Fit the hub adjusting nut and tighten by handwhilst rotating the hub until all end-play istaken up.Mount a dial gauge using bracket RO 530106and rest the stylus in a loaded condition onthe adjusting nut.
RR2771 M RO 530106
25.
26.27.
28.
29.
Slacken off the adjusting nut until a hubend-play of 0,013 to 0,05 mm (0.0005 to0.002 in) is obtained.Fit a new keyed lock tab washer.Fit and tighten the hub adjusting nut andrecheck the end-play before bending the locktab over.Fit a new joint washer to the driving memberand fit the member to the hub and securewith the five bolts tightening evenly to thecorrect torque.Fit the original drive shaft shim and securewith a circlip.
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FRONT AXLE & FINAL DRIVE . .
30. To check the drive shaft end-play mount a dialgauge using bracket RO 530106 and rest thestylus in a loaded condition on the end of thedrive shaft.
31. Fit a suitable bolt to the threaded end of thedrive shaft and using a pair of pliers move thedrive shaft back and forth noting the dialgauge reading. The end-play should bebetween 0.08 to 0,25 mm (0.003 to 0.010 in).
32. If the end-play requires adjustment, removethe circlip, measure the shim thickness and fitan appropriate shim to give the requiredend-play.
33. Remove the bolt from the drive shaft, fit thecirclip and dust cap.
34. Fit the brake caliper, see BRAKES section.35. Bleed the brake system, see ABS brake bleed
procedure.36. Fit the road wheel, remove the axle stands and
finally tighten the road wheel nuts.37. Operate the footbrake several times to locate
the brake pads before taking the vehicle onthe road.
FRONT DISCS ON VEHICLES Fill-ED WITH ABS
REMOVE, REFIT AND RECLAIM
Removing
1. Remove the front hub assembly.2. Remove the five hub to disc retaining bolts,3. Tap off the disc from the hub.
Refitting
4. Locate the disc on to the hub.5. Apply Loctite 270 and fit the hub to disc
retaining bolts. Tighten to the correct torque.
6. Using a dial indicator, check the total discrunout, this must not exceed 0,15 mm (0.006in). If necessary reposition the disc.
7. Fit the hub assembly.
Disc reclamation
Check the vented disc thickness. Thisdimension may be reduced to a minimumthickness of 22 mm (0.866 in).Material may be machined off the disc faces.On completion equal thicknesses of disc mustremain each side of the vent.
.i
ADDITION: SEPT. 89 13 ‘.. .
,
:
:
,. ,,. :
‘.
; .’
1,; ‘1,.‘~.‘.;,. 1.:
OVERHAUL FRONT STUB AXLE,CONSTANTVELOCITY JOINT AND SWIVEL ASSEMBLY ONVEHICLES FllTED WITH ABS
Service tools:18C 284AAH extractor.LST 132 bearing installer.LST 133 seal installer.
Remove stub axle, axle shaft and constantvelocity joint.
1.
2.3.
4.5.
Remove the hub complete as described in theoperation to overhaul the hub assembly onABS fitted vehicles.Drain the swivel pin housing and refit plug.Remove the six bolts retaining the stub axle tothe swivel housing.Remove the mud shield.Remove the stub axle and joint washer.
6. Pull out the axle shaft and constant velocityjoint from the axle casing.
Remove constant velocity joint from axle shaft
7.8.
9.
Hold the axle shaft firmly in a soft jawed vice.Using a soft mallet drive the constant velocityjoint from the shaft.Remove the circlip and collar from the axleshaft.
I
/--A I
RR 2783M \
Dismantle the constant velocity joint
10. Mark the relative positions of thevelocity joint inner and outer racecage for correct reassembly.
1.
constantand the
11. Tilt and swivel the cage and inner race toremove the balls.
I
ST1 025M .i
14 ADDITION: SEPT. 89
F R O N T A X L E & F I N A L D R I V E
12.
13.14.
Swivel the cage into line with the axis of thejoint and turn it until two opposite windowscoincide with two lands of the joint housing.Withdraw the cage.Turn the inner track at right angles to the cagewith two of the lands opposite the cageopenings and withdraw the inner race.
I
ST1026M
15
16.
17
Degrease and examine all components forgeneral wear and condition.Examine the inner and outer track, cage ballsand bearing surfaces of the constant velocityjoint for damage and excessive wear.To assemble the constant velocity joint,reverse the dismantling instructions andlubricate with a recommended oil.
18. Check that the end-float of the assembledjoint does not exceed 0.64 mm (0.025 in).
Fit constant velocity joint to axle
19.20.
Fit the collar and a new circlip.Engage the constant velocity joint on the axleshaft splines and using a soft mallet, drive thejoint home.
Renew stub axle,thrust ring, oil seal and bearing
21. Drill and chisel off the thrust ring taking careto avoid damaging the stub axle.
22. Remove the bearing and oil seal using specialtool 18C 284AAH and slide hammer. Ensurethat the fingers of the tool locate behind thebearing to drive it out. Repeat for the oil seal.
18G 284 AAH
ADDITION: SEPT. 89/REVISED: SEPT. 90 15
.FRONT AXLE & FINAL DRIVE 1990 KANCltROVER
Refit Remove swivel pin housing.
23. Lubricate the seal and lip with EP90 oil andwith the cavity side leading press in a new oilseal using special tool LST 133.
LST133---I
23
RR2760M
..’24.
.:
Using special tool LST 132, fit bearing with itspart number visible when fitted, and flush withthe end face of the stub axle.
RR2761M
25. Press fit a new thrust ring onto the stub axle
26. Remove the brake shield secured at thebottom by one nut and bolt, and midway bythe lock stop nut.
27. Disconect the track-rod end ball joint from thehousing.
28. Disconnect the drag-link ball joint.19. Disconnect the jump hoses from the brake
jump hose bracket.30. Remove the ABS brake sensor.31. Remove the six bolts securing the oil seal and
retaining plate to the swivel pin housing. Prisethe seal irom the swivel pin housing.
NOTE: The o i l sea l and re ta in ing p la tecannot be removed unti l the swivel pinbearing housing is removed.
32. Remove the two countersunk screws securingthe brake damper/shield bracket, and thelower swivel pin to the housing.
33. W i t h d r a w t h e l o w e r s w i v e l p i n a n d j o i n twasher by tapping the small protruding lug.
34. Remove the top swivel pin retaining boltscomplete with the brake jump hose bracket.
35. Withdraw the top swivel pin and shims.36. Remove the swivel pin housing while retrieving
the lower taper bearing.37. If the swivel pin housing is to be renewed, the
drain, level and filler plugs and lock-stop bolt.
38.
39.
40.41.
42.
Remove the seven bolts securing the swivelpin bearing housing to the axle case. Removethe swivel pin bearing housing.Remove and discard the oil seal and jointwasher.Drift out the lower swivel pin bearing track.Press out the top swivel pin bush housingassembly. Discard the thrust washer. From1991 model year, discard the thrust washersand bearing.If worn, pitted or damaged; renew the swivelpin bearing housing.
43. Press in a new lower swivel pin bearing track.
,, .‘,
Remove and overhaul swivel pin bearing housing
. . .i
16 ADDITION: SEPT. IJIREVISED: SEPT. 90‘.. . . . .
po;g 1990 FRONT AXLE & FINAL DRIVE 54r l
44. Press in a new bush and bush housing. Ensurethat the relieved lip of the bush housing facestowards the rear oil seal, as shown.
:
45.
46.
47.
48.
With the seal lips trailing press the axle shaftoil seal flush into the rear of the housing.Grease the lips.Fit a new thrust washer into the top swivel pinbush with t h e b l a c k P . T . F . E . coatinguppermost. Check it is in position when fittingthe top swivel pin. From 1991 model year fitnew thrust washers and thrust bearing.Hang the swivel pin bearing housing oil seala n d r e t a i n e r p l a t e o v e r t h e b ac k o f t hehousing. E n s u r e t h e y a r e i n t h e c o r r e c tassembly order.Fit a new joint washer and secure the swivelpin bearing housing to the axle. Starting withthe top fixing dowel bolt. Tighten evenly tothe correct torque.
Fit swivel pin housing
49.
50.
51.
52.
53.
54.
. . ..,.‘. .,.>:., 55.
,:’7 .
‘. ‘_.. 56.
Grease and fit the lower swivel pin bearing tothe bearing housing.Place the swivel pin housing in position overthe swivel pin bearing housing.Using a new joint washer, fit the lower swivelpin wi th l ip outboard. Do not secure wi thscrews at this stage.Fit a new sensor bush and new oil seal, lipside leading to the top swivel pin.Lubricate with a recommended oil and fit thetop swivel pin with existing shims.Coat the threads of the top swivel pin boltswith Loctite 542. Fit the bolts and jump hosebracket (do not tighten).Coat the threads of the lower swivel pinscrews with Loctite 270 and fit, together withthe damper and shield bracket. Tighten to thecorrect torque.Tighten the top swivel pin and brake jumphose bracket securing bolts to the correcttorque.
Check and adjust preload on bearings 1990model year
57 The preload on bearings to be 0,18 to 0,23mm (0.007 to 0.009 ins), without the swivelhousing oil seal and axle fitted, and readingfrom the centre of the swivel pin. The torquerequired to turn the swivel assembly from lockto lock to be 5.1 to 7.3 Nm (45 to 65 in.lbs).Adjust by removing or adding shims to the topswivel pin.
Check and adjust preload on bearings 1991model year on
58
The preload on bearings to be 0,25 to 0,30mm (0.010 to 0.012 ins), without the swivelhousing oil seal and axle fitted, and readingfrom the centre of the swivel assembly fromlock to lock to be 2.0 to 2.8 Nm (18 to 25in.lbs). Adjust by removing or adding shims tothe top swivel pin.To take a reading use special tool LST 141torque test adaptor, with a torque wrench andextension as shown.
/57 u , ‘
“L
RR2983M
Fit remaining components
59. Liberally apply (do not pack) a recommendedgrease between the lips of the swivel housingoil seal.
60. Secure the oil seal with the retaining plate andsecuring bolts tightening evenly to the correcttorque.
ADDITION: SEPT. 89/REVISED: SEPT. 90 17
KEY
1.2.3.4.5.6.7.8.9.
10.11.12.13.14.
TO DRIVE SHAFT AND SWIVEL ASSEMBLY
Brake caliper.Mud shield.Stub axle.feint washer.Oil seal.Bearing.Brake disc shield.C.V. joint.Circlip.Bush.Inner drive shaft.Top swivel pin and jump hose bracket.Shim.Swivel pin housing.
15. Joint washer.16. Lower swivel pin.17. Damper and shield bracket.18. Thrust washer.19. Bush and housing.20. Swivel pin bearing housing.21. Lower swivel pin bearing.22. Oil .seal.
RR2936M
23. Oil seal retaining plate.24. joint washer.25. Oil seal.26. Sensor bush.27. Thrust bearing.28. 1991 model year.
16
-
.F._ ”
FRONT AXLE & FINAL DRIVE
61. Fit the track-rod and drag link and secure withnew split pins.
62. Loosely fit the lock stop bolt for lateradjustment.
63. Fit the brake disc shield. Leaving the middlefixing nut loose until the lock stop has beenset.
Fit drive shaft and stub axle
64. Insert the axle shaft, and when the differentialsplines are engaged, push the assembly home.
CAUTION: Take care not to damage the axleshaft oil seals.
65. Place a new joint washer in position on theswivel pin housing to stub axle mating face.Coat the threads of the stub axle bolts withLoctite 270.
66. Fit the stub axle with the keyway at the I2o’clock position.
CAUTION: Ensure that the constant velocityjoint bearing journal is butted against thethrust ring on the stub axle. Before the stubaxle is secured.
67. Place the mud shield in position and securethe stub axle to the swivel pin housing withthe six bolts and tighten evenly to the correcttorque.
68. Fit the brake jump hoses to the brake jumphose bracket.
69. To complete the assembly, follow instructionsto fit front hub on ABS fitted vehicles.
70. Check that the swivel pin housing oil drainplug is tightly fitted and remove the filler andlevel plugs.
71. Inject approximately 0,35 litres (0.6 pints) ofrecommended oil until the oil reaches thelevel hole. Fit and tighten the filler and levelplugs and wipe away any surplus oil.
72. Set the steering lock-stop bolt to provide aclearance of 20mm (0.787in) between the tyrewall and radius arm. Tighten the locknut whichalso secures the brake disc shield.
7 3 . F i t t h e A B S b r a k e s e n s o r f o l l o w i n g t h einstructions in the brake section.
ADDITION: SEPT.89
: