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Land Rover Series III Part 5

Land Rover Series III Part 5

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Published by renatosartre

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Published by: renatosartre on Sep 10, 2011
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DIFFERENTIALASSEMBLY
Removeandrefit54.10.01Servicetool:601763BalljointextractorRemoving1Removethehalfshaftsandswivelaxles.54.20.01.2Drainthedifferentialhousing.3Disconnectthefrontpropellershaftatthefrontaxle.4Removethenutsandspringwasherssecuringthedifferentialtotheaxle.5Withdrawthedifferentialassemblyandgasket.Refitting6Ensurethatthematingfacesofthedifferentialflangeandaxlecasingareclean.Renewthegasket.7Reverseinstructions1to5.8Bleedthebrakes.
2RC2&9A
DIFFERENTIALASSEMBLY
Overhaul54.10.07
0708
6Liftoutthecrownwheel,differentialunitandbearings.7Removethesplitpin,slottednutandwasherssecuringthepinionflange.Flangeholdertool18G1205.8Withdrawthepinionflange.
continued
0706
Servicetools:Press47Pinionheightgauge.605004.Pinionheadbearingremover.18G47BK.Pinionbearingtrackremover/replacer.262757,262757/1.Spannerbearingnuts.530105.Dialgauge.18G191.Flangeholder.18G1205.Dismantling
It
isessentialthatdifferentialcomponentsaremarkedintheiroriginalpositionsandrelativetoothercomponentssothat,ifrefitted,theirinitialsettingismaintained.Notethatthebearingcapsmustnotbeinterchanged.1Removethedifferentialassemblyfromtheaxle.54.10.01.2Driftouttherollpinsecuringthebearingnutlockingfingerstothebearingcaps.Removethelockingfingers.3Slackenthebearingcapbolts.4Removethebearingadjustingnuts.5Removethebearingcapboltsandbearingcaps.
 
9Withdrawthe
pimon
completewithpinionheadbearingandouterbearingshims.Withdrawtheshims.10Removethepinionflangeoilseal,spacerandbearing.Discardtheoilseal.11Removethepinionheadbearingtrackandshimandtheouterbearingtrackfromthedifferentialhousing.Tool262757.12Removethepinionheadbearing.Tool18G47BK.13Removetheboltsandwasherssecuringthecrownwheeltothedifferentialflange.Withdrawthecrownwheel.14Removethedifferentialcarrierbear-ings.15Removethecirclipssecuringthedif-ferentialcrossshaft.Extractthecrossshaft.16Withdrawthedifferentialgearsandpinions.17Thoroughlyclean
all
components.Inspecting18Checkallbearingsforwearand/orpitting.
19
Checkallgearsforwear,scuffing,pittinganddamagedteeth.20Note:Thecrownwheelandpinionaresuppliedasamatchedset,andalsothepinionhousingandbearingcaps.16~
15--0
0704
07030707
AssemblingDifferentialgears21Fitthedifferentialgearstothedif-ferentialhousing.22Fitthedifferentialcrossshaftandretainingcirclips.23Checkthegearsforfreedomofrotationandbacklash.Nominalback-lashshouldbepresent.Excessiveback-lashwillnecessitaterenewalofthegearsand/orthedifferentialhousing.Noprovisionismadeforbacklashadjustment.24Ensuringthatthedifferentialhousingflangeandcrownwheelarethoroughlycleanfitthecrownwheel.Fitthecrownwheelboltsandwashersandevenlytighten.25Fitthecarrierbearingsandbearingtracks.26Placethedifferentialhousingcompletewithcrownwheelandbearingsinthepinionhousing.27Fitthebearingcapsandbolts.Donotfullytightenthebolts.
28
Fitthebearingadjustingnutsandadjusttoobtainzeroend-float.29Tightenthebearingcapbolts.
30
Usingadialgaugecheckthecrownwheelforrun-out.Thisshouldnotexceed0,10mm(0.004in.).Ifexces-siverun-outisrecordedremovethecrownwheelandexaminecrownwheelandmountingflangeforburrs,gritetc.Refitthecrownwheelandrecheck.Run-out,attributabletoabuckledordamageddifferentialhousingflangecanbecorrectedonlybyrenewingthedifferentialgearhousing.31Whensatisfiedthatrun-outiswithinthespecifiedlimitsremovethedif-ferentialhousingfromthepinionhousing.32RemovethecrownwheelboltsandrefitthemusingLoctiteStudloc.Evenlytightentheboltsto6,3to7,6kgf,
m
(45to55Ibf.ft.).
 
Pinion33Fitthepinionheadbearingtrackandtheoriginalshimtothepinionhous-ing.Tools262758,262757.
If
theoriginalshimwasdamagedormislaiduseanewshimofatleast1,27mm(0.050in.)thickness.34Fitthepinionouterbearingtracktothepinionhousing.35Fitthepinionheadbearingtothepinion.36Slidetheoriginalshim(bearingpre-load)intopositiononthepinionshaft.
If
theoriginalshimwasdamagedormislaiduseanewshimofatleast4,06mm(0.160in.)thickness.37Enterthepinioninitslocationinthepinionhousingandfittheouterbear-ingandspacer.38Fitthedrivingflange,washerandnut.Donotfittheoilsealatthisstage.39Withthepinionflangenuttightenedtoatorqueof9,6to16,5kgf.m(70to120lbf.ft.)theforcerequiredtorotatethepinionshaftshouldbewithin6,9to28,7kgf.em(6to25Ibf.ins.)wheninitialinertiahasbeenovercome.Changethebearingpre-loadshimasnecessarytoobtainthisre-quirement.Athickershimwillreducepre-load;athinnershimwillincreasepre-load.40Locatethepinionheightgaugeinthepinionhousingandsecurewiththebearingcaps.NOTE:Fourvariationsofheightgaugeare
in
use.Theseare601998,262761,600299and605004;anyofthesegaugesmaybeused.41Placetheslipgaugeonthepinionfaceandholdfirmlyinplace.
0705
42Usingfeelergaugesmeasuretheclearancebetweentheslipgaugeandtheheightgauge.Therequiredclearanceis:Heightgauges601998,262761and600299.-0,07to0,10mm(0.003to0.004in.).Heightgauge605004.-0,28to0,30mm(0.011to0.012in.).Determinetheshimthicknessrequiredforthepinionheadbearingtoobtaintheaboverequirement.
38
43Removethepinionheadbearingtrackandsubstituteashimofthecalculatedthickness.NOTE:Adjustmenttothepinionheadshimwillnecessitateanequalplusorminusadjustmenttothebearingpre-loadshim.
44
Refitthepinionheadbearingandrecheckclearance(Instruction42).45Ifclearanceissatisfactoryremovethepinionheightgauge.
If
clearanceisincorrectrepeatinstruction43.46Removethepinionflange.47Smeartheouterperipheryofthenewpinionflange
oil
sealwithjointingcompound.Fittheoilseal(seallipstowardsthepinion).48Lubricatetheseallipsandfittheflange,nutandsplitpin.Nuttorque(70to120lbf.ft.).49Placethedifferentialhousinginthepinionhousing.50Fitthebearingcapsandbolts.Donotfullytightenthebolts.51Fitthebearingadjustingnuts.52Setcrownwheel/pinionbacklashto0,20to0,25mm(0.008to0.010in.)withzeroend-float.MovetheserratedadjustingnutsindirectionAtoreducebacklash:moveindirection
B
toin-creasebacklash.53Tightenbothadjustingnutshalfaserration.54Evenlytightenthebearingcapboltstorque8,3kgf,m(60Ibf.ft.).55Recheckcrownwheel/pinionbacklash.56Bendthelockingfingerstoaccom-modateadjustingnutserrationsasrequired.Fitthelockingfingersandrollpins.57Lubricatethebearingsandgears.
0709
7.6to13
kgf.
em
(7
to12Ibf.ins.)Gauges.601998,262761,6002990,07to0,10mm(0.003to0.004
ins.)
Gauge.6050040,28to0,30mm(0.011to0.012in.)0,10mm(0.004in.)0,20to0,25mm(0.008to0.010in.)DATAPinionbearingpre-loadPinionheightsetting.Crownwheelrun-out.Crownwheel/pinionbacklash.

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