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1987

REAR AXLE & FINAL DRIVE

REAR AXLE
Remove and Refit
Removing
WARNING: The removal and refitting of the axle
from the vehicle requires the assistance of a
further two personnel to steady the axle, when
lowering 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 any
excess of fluid is stemmed.
7. Disconnect the pad wear multi-plug at the
bracket mounted on the underside of the
floor. Pry the rubber grommet out of the
bracket and feed the plug through the hole.
8. Disconnect the lower links at the axle.

9. Mark the differential and drive shaft drive
f l a n g e s w i t h i d e n t i f i c a t i o n m a r k s to aid
re-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 the
axle bracket.
11. Release the bolts and remove the coil spring
retaining 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, and
tighten the bolts to the specified torque (see
section 06-Torque values).
15. Reverse the removal instructions.
16. Tighten the pivot bracket ball joint to axle to
the specified torque (see section 06-Torque
values).
17. Tighten the drive shaft to differential drive
flange to the specified torque (see section
06-Torque values).
18. Refill the brake system and bleed as described
in Section 70.

REVISED: MARCH 90

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OVERHAUL AXLE DIFFERENTIAL ASSEMBLY
Service Tools:
-Flange holder tool
-Pinion height setting gauge
-Universal setting block
-Pinion head bearing remover/
replacer
LST106
-Oil seal replacer
R0262757A -Extractor for pinion bearing races
R0262757-1 -Replacer-use with R0262757A
R0262757.2 -Adaptor tail bearing cap replacer
-Wrench flange and carrier bearing
R0530105
nuts
-Bracket for dial gauge and
R0530106
indicator
-Press
MS47
1861295
18C191
186191-4
18647-6

7. Remove the cotter pin securing the pinion
flange nut.
8. Remove the pinion flange nut using service
tool 18C1205 to restrain the flange.

DISMANTLE
It is essential that differential components are
marked in their original positions and relative to
other components so that, if refitted, their initial
setting is maintained. Note that the bearing caps
must not be interchanged.
1. Remove the axle shafts then the differential
assembly from the axle.
2. Drive out the roll pin securing the bearing nut
locking fingers to the bearing caps. Remove
the locking fingers.
3. Loosen the bearing cap bolts and mark the
caps for re-assembly.
4. Using service tool R0530105, remove the
bearing adjusting nuts.
5. Remove the bearing cap bolts and bearing
caps.
6. Lift out the crown wheel, (ring gear)
differential unit and bearings.

S T & M

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9. Withdraw the pinion complete with pinion
head bearing and outer bearing shims.
Withdraw the shims.
10. Remove the pinion flange oil seal, spacer and
bearing. Discard the oil seal.

ST506M

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REVISED: MARCH 90

FOE; 1989

REAR AXLE & FINAL DRlVE

11. Using service tool R0262757A, remove the
pinion head bearing track and shim and drive
out the outer bearing track from the
differential housing.
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ST509M
INSPECTION

RR2666E

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12. Remove the pinion head bearing with service
tool MS47 and adaptor 18G47-6.

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 pinion
housing and bearing caps.
ASSEMBLE
Differential gears

,.

21. Fit the differential gears to the differential
housing.
22. Fit the differential cross shaft and retaining
circlips.

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ST508H

13. Remove the bolts and washers securing the
crown 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.
ST5lOM

REVISED: DEC. 88

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Tighten the bearing cap bolts to the specified torque (see section 06-Torque values). . grit. This should not exceed 0.27 mm (0.. Do not fully tighten the bolts. Check that the serial number marked on the pinion end face matches that marked on the crown wheel.o u t i s w i t h i n t h e specified limits remove the differential housing from the pinion housing. Place the differential housing complete with crown wheel and bearings in the pinion housing.004 in).. Fit the carrier bearings using a suitable press or drift and assemble the tracks traces) to the bearings.050 in) thickness.10 mm (0.’ Ii\ q-q-+ 7--i - . . 28. Run-out. 33 Remove the crown wheel bolts and refit them u s i n g L o c t i t e ‘Studlock’. E v e n l y t i g h t e n t h e b o l t s t o t h e s p e c i f i e d t o r q u e (see s e c t i o n 06-Torque values).r. Excessive backlash will necessitate replacement of the gears and/or the differential housing. Refit the crown wheel and recheck. If excessive run-out is recorded remove the crown wheel and examine crown wheel and mounting flange for burrs.a i-77 - RR2666E 4 v 3 t i REVISED: DEC. Using a dial gauge check the crown wheel for run-out. 32. _. Fit the pinion head bearing track and the original shim to the pinion housing using service tools R0262757A and R0262757-1. Fit the bearing adjusting nuts and adjust to obtain zero end-float. If the original shim was damaged or mislaid use a new shim of at least 1. Fit the bearing caps and bolts. 27. 25.1989 “R^o”v’. 31. W h e n s a t i s f i e d t h a t r u n . to a buckled or damaged attributable differential housing flange can be corrected only by replacing the differential gear housing.. 26 ‘. 24. Ensuring that the differential housing flange and crown wheel are thoroughly clean fit the crown wheel. Check the gear for freedom of rotation and backlash. . REAR AXLE & FINAL DRIVE 23. etc. No provision is made for backlash adjustment.. 26. 29. 88 ‘. Nominal backlash should be present. 25 30.

:: .g. 88 5 <. 37.’ 1989 REAR AXLE & FINAL DRIVE 35. Fit the driving flange.. NOTE: If using original bearings. Do not fit the oil seal at this stage. Tighten the pinion flange nut slowly until the force required to rotate the pinion is 23 to 40.: 36. 38. Fit the pinion head bearing to the pinion using service tool 18G47-6. Do not fit the shims for bearing pre-load at this stage. Fit the pinion outer bearing track to the pinion housing with service tools R0262757A and R0262757-2. REVISED: DEC. . This will pre-load the bearings in order to check the pinion height dimension. 40.25 kgf cm (10to 15 in lb) Drive pinion markings 42. washer and nut. the pre-load figure is 11. 39. . Fit the outer bearing and spacer.5 to 17.. The markings on the end face adjacent to the serial number are of no significance during servicing. 41. Enter the pinion into its location in the pinion housing. : ‘.25 kgf cm (20 to 35 in lb) if new beatings are fitted. which are bedded in.

PINION HEIGHT SHIMS r- PART No. 49.O% . a minus (-) pinion must be set above nominal. in thousandths of an inch.17 1. 88 .37 1.1 9 8 9 KANClt ROVER REAR AXLE & FINAL DRIVE 43.038 .02 1. i :.52 ST517M ‘. . Note whether the trace pin has moved up or down from the zeroed setting.050 . Ensure that the pinion end face is free of raised burrs around the etched markings.042 . 47. Where the trace pin has moved down.22 1.97 . The nominal setting dimension is represented by the setting gauge block 18C191-4 which is referenced from the pinion end face to the bottom radius of the differential bearing bore.07 1. Use only the 39. Use of a surface plate is recommended.048 . the amount is equivalent to the thickness of shims that must be removed from under the pinion inner track to bring the pinion down to the nominal position. . : ST518M 6 REVISED: DEC. The figure marked on the end face opposite to the serial number indicates.044 . / .32 1. the deviation from nominal required to correctly set the pinion.’ . An unmarked pinion must be set at nominal.12 1. 549230 549232 549234 549236 549238 549240 549242 549244 549246 549248 549250 549252 INCH MM . I . Add together the readings then halve the sum to obtain the mean reading. Position the dial gauge centrally on the pinion end face with the trace pin registering on the lowest point on one differential bearing bore. a.046 .47 1. Place the dial gauge and setting block on a flat surface and zero the dial gauge trace pin on the setting block.054 0.42 1. 46. Repeat on the other bearing bore. Drive pinion adjustment 45.060 1.058 . NOTE: The setting block has three setting heights as follows.50mm setting mark for this differential.’ 44. Note the dial gauge deviation from the zeroed setting. A pinion marked plus t +) must be set below nominal.27 1. Remove the keep disc from the magnetized base of dial gauge tool 18Gl91. 48.040 .052 .

A l t e r n a t i v e l y . 54. of the same thickness as the originals (bearing pre-load) into position on t h e p i n i o n s h a f t . Before adjusting the shim thickness.REAR AXLE & FINAL DRIVE r b. the pre-load figure is 11.63 1. check the pinion face marking and if it has a plus (+) figure. Adjust the shim thickness under the pinion head bearing track as necessary.25 kgf cm (10 to 15 in lb) 59.57 I. 58.075 .060 . Change the bearing pre-load shim as necessary to obtain this A thicker shim will reduce requirement. 50.I5 . If t h e o r i g i n a l s h i m w a s damaged or mislaid use a new shim of at least 4. 51.072 . INCH MM FRC1193 FRCl195 FRC1197 FRC1199 FRCI 201 FRCl203 539718 539720 539722 539724 .070 . outer bearing and spacer.06 mm (0. when initial inertia has been overcome. Fit the driving flange.. 55. I REVISED: JULY 88 7 .064 . subtract that amount in thousandths of an inch from the shim thickness figure obtained in the previous item.83 1.78 1. For example. 57.005 .002 . = = = = = = = = = = MM .074 . with an end face marking of +3.20 . washer and nut. PINION PRELOAD SHIMS PART No. pinion.125 .03 Fitting Pinion Oil Seal :. the dial gauge reading should indicate that the pinion is + 0.225 . If the setting is correct. CAUTION: Before fitting the new seal to the differential. the amount is e q u i v a l e n t t o t h e a d d i t i o n a l thickness of shims required to bring the pinion up to the nominal position.. :’ INCH . add the amount to the shim thickness figure.080 I.004 .160 in) thickness.25 kgf cm (20 to 35 in lb) using new bearings.25 NOTE: DIAL INDICATOR IS METRIC! Conversion must be made to SAE (INCH) UNITS when performing measurements and selecting shims. Recheck the pinion height setting. A small scratch on the seal lips could impair its efficiency. Remove the pinion flange.5 to 17. Bearing pre-load adjustment 53.OlO . Enter the pinion in its location in the pinion housing and fit the outer bearing and spacer.025 .006 ..068 . Tighten the pinion flange nut to the specified torque (see section 06-Torque values). a thinner shim will increase pre-load. Slide new shims.93 2.I0 . Where the trace pin has moved up. NOTE: If using original bearings.009 . the mean reading on the dial gauge will agree with the figure marked on the pinion end face.88 1. examine the seal to ensure that it is clean.175 .003 in.007 . 51 l . 56. undamaged and that the garter spring is properly located. which are bedded in.05 .68 I. pre-load. Do not fit the oil seal at this stage. i f t h e p i n i o n h a s a m i n u s (-) figure.076 .52 1.003 .062 .008 . 52.OOl ‘. The force required to rotate the pinion shaft should be within 23 to 40. Remove the pinion flange.066 .73 1.

I 67. loosening the left hand bearing adjuster nut. 63. lip side leading squarely on the pinion nose housing and drive the seal into position flush with the end face of the housing using seal replacing tool LST106.-* . Fit the bearing adjusting nuts. 8 REVISED: JULY 88 i .10 to 0. Lightly lubricate the seal lips with a recommended oil. ST522M 65. D O N O T slacken the r i g h t h a n d n u t a t a n y t i m e . Tighten the left hand nut slowly until it contacts the bearing. using service tool 530105. Fit the distance piece and flange and secure with washer and nut. Place the differential housing in the pinion housing. 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 n wheel/pinion backlash is just removed.e. Coat the outer diameter of the new seal width with an all purpose grease and fit the seal. othmwse the bearing preload will be affected. . 62.17 mm (0 004 t o 0 . Push the crown wheel into mesh with the pinion. Tighten the nut to the specified torque and fit a n e w c o t t e r p i n ( s e e s e c t i o n 06-Torque values). 0 0 7 i n ) i s a c h i e v e d . 64.’ . . RR96sM CROWN ADJUSTMENT J WHEEL/PINION BACKIASH : CAUTION should also be taken when performing Backlash Setup i. 66. Continue turning the left hand nut until a backlash of 0. convert metric readings to inches. RR968M 61. Do not fully tighten the bolts. Fit the bearing caps and bolts.1 9 8 7 ROVER lcANGE REAR AXLE & FINAL DRIVE 60.

. 70. . . by machining an equal amount off each face.. ... 11. . 0.. I. . . .... See Section 06 for tightening torques. .15 mm (0. ... 1. Refitting (.. .REAR AXLE & FINAL DRIVE :. casing clips and remove the brake caliper retaining bolts and secure the assembly to one side.. 23 to 40. . DATA Pinion bearing pre-load: (new bearings) .006 in).. lower on to axle stands and remove the road wheels. Evenly tighten the bearing cap bolts to the specified torque (see section 06-Torque values)... ...... ... Remove the rear disc fixing bolts... .. .004 in) Crown wheel/pinion backlash ...510 in) front and 12 mm (0.. Using a dial indicator. ... Fit the disc fixing bolts.. . RR984M REVISED: MARCH 90 9 .. 2.. . 3. 5. 0... Fit the rear hub assembly. 2.. .... this must not exceed 0. 68.17 mm (0.. ... . 6. .. Remove the rear hub assembly. Tal e care not to kink the brake hose... If necessary...... ...007 in) REAR DISCS 7............. REMOVE AND OVERHAUL REAR HUBS 4.. . If necessary reposition the disc.... ...10 to 0. 71. tighten the adjustment nuts slightly to align the locking finger with a slot. 1 3 Service tools: Oil seal replacer -LST550-5 Drift for above tool -MS550 or 186134 Hub nut wrench -606435 Remove 1.25 kgf cm (IO to 15 in lb) Crown wheel run-out . Remove and refit Disc Reclamation Removing Check the disc thickness marked on the disc boss-this dimension may be reduced to a minimum thickness of 13 mm (0..... check the total disc run out. Jack-up the vehicle.. Release the brake hose from the axle......004 to 0. :. Remove the five bolts securing the axle shaft to the hub and withdraw the shaft..460 in) rear. . . . Tap off the disc from the rear hub.. . Recheck crown wheel/pinion backlash. .. .. . .. . ..10 mm (0. . .. Fit the locking fingers and roll pins. . Locate the disc onto the rear hub. .. .. .5 to 17....:.... . .25 kgf cm (20 to 35 in lb) (bearings bedded in) . 69.. Lubricate the bearings and gears.......>.

:: 10 REVISED: MARCH 90 -- . 5. Assemble 13. Likewise remove the inner nut.1987 kANbc ROVER REAR AXLE & FINAL DRIVE 4. 8. Withdraw the hub complete with bearing oil seals and brake disc. Bend back the lock tab and remove the outer nut using box wrench 606435 and remove remove the lock washer. 12. Examine the stub axle and in particular check that the inner seal track is smooth and free from blemishes. Coat the threads of the retaining bolts with Loctite 270 and tighten evenly to the correct torque (see section OC-Torque values). Mark the relationship of the hub to the disc if the original parts are to be re-assembled. 6. Remove the inner and outer oil seals. 14. Degrease and examine the hub and brake disc and if necessary replace both or whichever part is unserviceable. Remove the inner and outer bearing cones (races). Drive-out the inner and outer bearing cups. Remove the seal track spacer. using a suitable drift or commercial bearing race driving tool. If necessary remove the six retaining bolts and remove the stub axle complete with the mudshield and joint washer. 7. 10. Fit the new inner and outer bearing cups to the hub. - 1 I. 9. Using a new joint washer fit the stub axle and mud shield. The disc is attached to the hub with five bolts.

seal lip leading. squarely on the hub and using the 72 mm end of seal replacer tool LSTSSO-5and drift 550 or l8Gl34.004 in).013 to 0. 88 ‘11 :.. 21. Place the seal. squarely on the hub and using the 76 mm end of seal replacer tool LSTSSO-5and drift 550 or 18C134. Taking care not to damage the seal lips fit the hub assembly to the stub axle. 1 Fitting outer oil seal 20. Carefully fit the seal track spacer. Fitting hub to stub axle 23. 18. 17. lip side leading. Carry out instructions 16 to 18.. This is important since a dry seal can be destroyed during the first few revolutions of the hub. Fit the new outer bearing cone and pack with one of the recommended hub greases. . lip side leading. Although the new seal is already pre-greased by the manufacturer. Clean the hub oil seal housing and ensure that the seal locating surface is smooth and the chamfer on the leading edge is also smooth and free from burrs. 25. Continued . Even a small scratch on the seal lip could impair its efficiency. flush with the end face of the hub. 24. taking care not to damage the lip. drive the seal into position.0005 to 0. 19. REVISED: APR.10 mm (0. 16. 26. Fit the hub inner nut and using wrench 606435 tighten the adjusting nut while slowly revolving the hub until all end-float is removed. then back-off the nut approximately half a turn and retighten the nut to 13-15 in lb which will automatically allow for compression of the rubber on thP new seal track spacer giving the required hub end-float of 0. Select a new seal track spacer and check that the outer diameter is smooth and free from blemishes and that there are no burrs on the chamfered leading edge. Do not allow the weight of the hub to rest even temporarily on the outer seal otherwise damage and distortion could occur. Examine the new seal and ensure that it is clean and undamaged and that the garter spring is properly located. drive the seal into position to the depth determined by the tool. Therefore hold the hub clear of the stub axle until the seal track spacer is fitted. Coat the lips of both seals with one of the recommended greases.REAR AXLE & FINAL DRIVE [ii 15. NOTE: Instruction 26 is applicable to hubs that have been fitted with new components throughout. Fitting new oil seal-inner . If original components are being refitted instruction 27 must be followed using the adjustment nut to achieve the required end-float. apply one of the recommended hub bearing greases to the outside diameter of the seal before fitting. Place the seal. 22. Fit the new inner bearing cone and pack with one of the recommended hub greases.

Using a new joint washer. 12 REVISED: APR. 28. Secure the brake pipes to the axle casing. 88 . If original components have been refitted rotate the hub several trmes to settle the bearings then recheck the end-float. refer to previous note and instruction 27. lower the vehicle to the ground and tighten the road wheel nuts evenly to the correct torque. RR709M 30. Fit the brake caliper and secure with the retaining bolts and tighten to the correct torque (see section 06-Torque values). Fit the road wheels. tighten the outer lock nut to 70 to 80 ft lb (95 to 108 Nm). Bend one segment of the lock washer over the adjusting nut and another. Restraining the inner adjustment nut. Rotate the hub to settle the bearings and check the end-float by pushing and pulling the hub. End-float must fall within the limits given in the previous instruction. 29.r-t 1987 KANClc ROVER 51 REAR AXLE & FINAL DRIVE 27. diametrically opposite. 31. If the rubber on the seal track spacer has p r e v i o u s l y b e e n compresssed t h e h u b end-float can be checked by mounting a dial indicator and bracket on the hub so that the trace pin rests in a preloaded condition on the nut. Fit a new lock washer and locknut. fit the hub driving’ shaft and evenly tighten the retaining bolts to the correct torque (see section 06-Torque values). jack-up the vehicle. 30”’ 33. remove the axle stands. over the locknut taking care not to damage the outer seal. 32.

14. :.._ I.*. 2..: ..j . .. 10. :.. 9. 12.A’.. 13. 1. Inner bearing cup Inner bearing cone Inner oil seal Mudshield Stub axle Stub axle joint washer Brake disc REVISED: APR.. 17.- KEY TO REAR HUB COMPONENTS 1. 6. Rear axle shaft joint washer locknut Lock washer Adjusting nut Seal track spacer Outer oil seal Outer bearing cone Outer bearing cup Hub 11. : . 15. 88 v 13 .I.... 4. .. 3. 5. 16. .: x . 7.’: REAR AXLE & FINAL DRIVE i. 8.

16. 3. 7. KEY TO REAR HUB COMPONENTS 1. Release the brake pipe from the axle. 17. . Remove the keyed washer. 3. 8. Should m 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 hub with studs must be obtained. Bend back the lock washer tab. Mark. Sensor ring. OVERHAUL AND REFIT Service tools: Hub oil seal replacer LST 137. 10. 6. 89 . Keyed washer. Inner bearing. REAR AXLE & FINAL DRIVE REAR HUB ASSEMBLY ON VEHICLES ANTI-LOCK BRAKES (ABS) FIT-TED WITH REMOVE. 15. Withdraw the hub and brake disc assembly complete with bearings. 5. 6. ‘. 2. Hub adjusting nut. 8. Remove the outer bearing. Remove the five bolts and separate the hub from the brake disc. Dust cap. Outer bearing. Remove the five bolts and withdraw the driving member and joint washer. 11. Drive member joint washer.g$. 2. 13. jack up the vehicle. Remove the circlip from the rear axle shaft. Dial gauge bracket RO 530106. Remove the locknut and tab washer. 5. 10. casing clips and remove the brake caliper retaining bolts then secure the assembly to one side. 15. 1 . Remove 1. Sensor ring retaining nut. 4. Hub. Drift out the inner and outer bearing tracks. Slacken the rear wheel nuts.‘) : 4 ADDITION: SEPT. 12. 13. WARNING: Take care not to kink the brake pipe. the relationship between the hub and brake disc. Lock nut. Drift 18C 134. Drive member retaining bolt (five off).: RR2766M ‘6 ‘. Remove the five nyloc nuts and withdraw the sensor ring. 14. Lever off the dust cap. Disc retaining bolt (five off). Remove the hub adjusting nut. Grease seal. 11. 16. Lock washer. Circlip.1 9 9 0 . 7. lower onto axle stands and remove the road wheel. Brake disc. for reassembly. if original hub is to be refitted. 9. Drift out the grease seal and inner bearing from the hub and discard the seal.. WARNING: A maximum of two road wheel retaining studs can be renewed. 14. 12. 9. 4. Drive member.

22. Fit the sensor ring using new nyloc nuts. Fit the keyed washer.I. . . the end-play before bending the lock tdb over. 23. 24. Applying Loctite 270. . Fit the hub adjusting nut and tighten by hand whilst rotating the hub until all end-play is taken up. 31 Fir a new joint washer to the driving member and frt the member to the hub and secure with the five bolts tightening evenly to the correct torque.:‘-.0005 to 0..002 in) is (~l~ralned. 19.R”^o”. ::. Assemble the brake disc to the hub. . .. Grease as in instruction 18 and fit the outer bearing to the hub.’ RR2772M LST137 . 21.’ . . With the lip side leading fit a new seal to the hub using special tool LST 137 seal replacer and drift 18G 134.. 26._ . .. RO 530106 15 . fit and tighten the five retaining bolts to the correct torque. to the marks made during dismantling. Pack the hub inner bearing with a recommended grease and fit to the hub. (11I I I a n d t i g h t e n t h e h u b a d j u s t i n g n u t a n d I(‘( heel. 1 9 9 0 REAR AXLE & FINAL DRIVE Refit 20. 89 . 27. ensuring it is correctly fitted to avoid tooth run out. lining up 17. Clean the stub axle and rear axle shaft and retract the ABS sensor slightly from sensor sleeve. 18. . If necessary renew any sensor ring studs applying Loctite 270 where the stud screws into the sensor ring. Mount a dial gauge using bracket RO 530106 and rest the stylus in a loaded condition on the adjusting nut.05 mm (0. ‘. Apply grease between the seal lips. I RR2770M 4 ADDITION: SEPT. 2’1 I II a new keyed lock tab washer. Clean and degrease the hub and drift in the inner and outer bearing tracks.’ _.. Drive in the seal so that it is flush with the rear face of the hub. Fit the hub assembly to the stub axle. 25.’ I 28 Gcken off the adjusting nut until a end-play (110 013 to 0.

Refit the hub assembly complete as described in the operation to refit the hub assembly instructions 23 to 37. 2. Lubricate the seal and lip with EP90 oil and using special tool LST 138 fit a new oil seal lipside trailing so that the seal is flush with the rear face of the stub axle... Stub axle to axle casing bolt. Push the sensor through the bush until it touches the sensor ring. 35. Refit 6.’ . Rear axle shaft.i REAR AXLE & FINAL DRIVE 32. Fit the dust cap.. Renew rear stub axle oil seal 1. Fit the circlip to the rear axle shaft. Remove the hub complete as described in the operation to overhaul the hub assembly instructions 1 to 10. 34. KEY TO STUB AXLE COMPONENTS 1. The sensor sets to its correct position when the hub is rotated. 3. Mudshield. 7. Remove the stub axle and joint washer. RR2759M ADDITION: SEPT. 3.1990 R”d. 4. Operate the footbrake several times to locate the brake pads before taking the vehicle on the road. Sensor bush sleeve. Secure the brake pipes to the axle casing. 37. Remove the mud shield. 4.. ensuring that it locates in the groove. ‘\ ) . 2. . Fit the road wheel. axle shaft 1. OVERHAUL AND REFIT Remove rear stub axle. Drift 18G 134. REAR STUB AXLE ON VEHICLES FlITED Special tools: Oil seal replacer LST 138.. to the axle casing tightening evenly to the correct torque. remove the axle stands and finally tighten the road wheel nuts. Stub axle joint washer. 6. 33. Set the ABS brake sensor. 7. Fit the brake caliper and tighten the two bolts !o the correct torque. 36. Carefully fit the rear axle shaft to avoid damaging the stub axle seal. Remove and discard the oil seal. WITH ABS REMOVE. 5. the stub axle and mudshield with the retaining bolts.-. 5 . Using a new joint washer fit. Pull-OUI t h e r e a r a x l e s h a f t f r o m t h e a x l e casing. > .. Axle case. Stub axle.: . 8. Remove the six bolts retaining the stub axle to the axle casing. 89 kd .

4. 89 17 . Remove the five hub to disc retaining bolts. . 7 .15 mm (0. Remove the five nyloc nuts.‘. ‘-i.460 in). 5. Remove the sensor ring. 10. . 9. Fit the hub assembly. Using a dial indicator. Using new nyloc nuts fit the sensor ring. Tap off the disc from the hub. If necessary reposition the disc. Disc Reclamation Check the disc thickness. REFIT AND RECLAIM Removing 1.REAR AXLE & FINAL DRIVE REAR DISCS ON VEHICLES FllTED WITH ABS REMOVE. Tighten to the correct torque. This dimension may be reduced to a minimum thickness of 12 mm (0. 3.006 in). 8. Refitting 6. Locate the disc onto the hub. :. Apply l o c t i t e 2 7 0 a n d f i t t h e h u b t o d i s c retaining bolts. this must not exceed 0. Equal amounts must be machined off both sides of the disc._. check the total disc runout. Remove the rear hub assembly. 2. ADDITION: SEPT.

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8. 6. ‘. 21. i RR742M 11. Position the axle under the vehicle. Mark the differential and drive shaft flanges with identification marks to aid re-assembly. Remove the brackets and refit the bolts to prevent oil leakage. 12. tie the drive shaft to one side.y. RR983M Remove the nuts and washers securing the shock absorbers to the axle. Using a suitable extractor disconnect the drag link from the swivel pin housing arm. Tighten the panhard rod to axle bracket to the specified t o r q u e ( s e e s e c t i o n 06-Torque values).roFf. Refitting : ‘_’. 20. 9. Remove the two nuts and bolts securing the panhard rod to the axle bracket and lift the rod clear of the axle. supporting the left hand side of the axle.:. Withdraw the axle assembly. Remove the nuts securing the radius arms to the chassis frame side members. 17. 22. 7. REVISED: JULY 88 . 14. Support the axle weight with a suitable hydraulic jack. 1987 FRONT AXLE & FINAL DRIVE FRONT AXLE ASSEMBLY 153 Remove and refit ll& 6\ Removing !. 18. Reverse the removal instructions. : : 16. 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 e s 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-Torque values). Remove the bolts securing the brake calipers and tie the calipers to one side. Tighten the radius arms to axle bolts to the specified t o r q u e (see s e c t i o n 06-Torque values). E W A R N I N G : The removal of the axle from the vehicle will require the assistance of two further personnel to steady the axle when lowering from the vehicle. Tighten the upper swivel pin retaining bolts to the specified torque (see section 06-Torque values). Disconnect the brake pad wear electrical multi-plug at the rear of the caliper (where applicable). Remove the front road wheels. Jack up the front of the vehicle and support the chassis frame. 23. Carefully lower the axle assembly and remove the road springs. 15. Tighten the drive shaft to differential bolts to the specified torque (see section 06-Torque values). Lower the radius arms and withdraw them from the chassis side members. Remove the four nuts and bolts. IO. 13. 19. 5. Remove the two bolts from the top of the swivel pin housings securing the brake hose brackets. Remove the four nuts and bolts securing the radius arms to the axle bracket. Disconnect the steering damper at the tie rod and using a suitable extractor remove the tie rod ends from the swivel pin housing arm.

:. 25. ... . this must not exceed 0... 24.15 mm (0..I. FRONT DISCS Remove and refit Removing 1. Remove the front disc fixing bolts. Fit the disc fixing bolts. 2 REVISED: JULY 88 .i . 3. Using a dial indicator. Tap the disc off the front hub. check the total disc run-out. See Section 06 for tightening torques.. Tighten the track rod end to the specified torque and fit a NEW cotter pin (see section 06-Torque values).. Fit the front hub assembly. If necessary. Remove the front hub assembly.( . Tighten the radius arms to chassis side member nuts to the specified torque (see section 06-Torque values). .:’ . 6.. Locate the disc onro the front hub.. 5...‘. : . When overhauling the front differential refer to the rear differential overhaul procedure in Section 51 of this manual.006 in). FRONT DIFFERENTIAL-OVERHAUL 1 The front and rear differentials fitted to Range Rover are the same type. reposition the disc. 7.. 3 Refitting 4.“.:. .‘. 2.

... 4. Withdraw the hub complete with bearings........... Remove the seal track spacer..... 6. Remove the inner and outer oil seals... Brake disc . REVISED: FEB... Similarly...... 8... Stub axle joint washer 17.- I’ .. Remove the inner and outer bearing cones.... Hub driving shaft Gasket Locknut Lock washer Adjusting nut Seal track spacer Outer oil seal 13. 2. Hub nut wrench ....... 9.. lower onto axle stands and remove the road wheels. 3. 11..I PO......... ... 10.......... 2........ Bend back the lock-tab and remove the outer nut using wrench 606435 and remove the lock washer............ Mudshield 15. 1987 FRONT AXLE & FINAL DRIVE l-l54 REMOVE AND OVERHAUL FRONT HUB Service tools: Oil seal replacer ....... Remove the brake caliper retaining bolts and release the assembly from the brake disc and secure to one side. 5.. 8.. Drift for above tool ... 9.. Remove the swivel housing top bolt to release the brake hose bracket.. oil seals and brake disc........ 7. LSTSSO-5 MS550 o r 18Gl34 606435 KEY TO FRONT HUB COMPONENTS 1..... 5..........i ‘_ Remove 1. 6. Inner oil seal 14... lack-up the vehicle.... Stub axle 16. Remove the five bolts retaining the hub driving shaft and withdraw the shaft from the hub....’ ........ 7.. 4.. 12.... 87 3 . remove the inner nut............ 3.....

use a suitable brass drift or commercral race driver to prevent damage to the bearing cups. Fit the new inner bearing cone and pack with one of the recommended i xubgreases.. Mark relation of hub to disc as necessary RR070M 16. Using a new joint washer fit the stub axle and mudshield. Degrease and examine the hub and brake disc and fit new components where necessary. The brake disc is attached to the hub by five bolts. Complete with the mudshield and joint washer.r 54 1987 KANCIE ROVER FRONT AXLE & FINAL DRIVE 10. I 11. Drive out the inner and outer bearing cups. Examine the new seal and ensure that it is clean and undamaged and that the garter spring is properly located. 15. . Fitting new oil seal-inner 1’6.’ . Even a small scratch on the seal lip could impair its efficiency. REVISED: FEB. Clean and examine the stub axle and in particular check that the inner seal track diameter is smooth and free from blemishes. Clean the hub oil seal housing and ensure that the seal locating surface is smooth and the chamfer on the leading edge is also smooth and free from burrs. Fit the new inner and outer bearing cups to t h e h u b .. 13.- Assemble 14. Coat the threads of the retaining bolts with Loctite 270 and tighten evenly to the specified torque (see section 06-Torque values). If necessary remove the retaining bolts and withdraw the stub axle. . 87 .- \. 4 17. 18.

Fitting outer oil seal . drive the seal into position flush with the end face of the hub. Select a new seal track spacer and check that the outer diameter is smooth and free from blemishes and that there are no burrs on the chamfered leading edge. If original components are being 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 e followed using the adjustment nut to achieve the required end-float. Rotate the hub to settle the bearings and check the end-float by pushing and pulling the hub.10 mm (0. Fit the hub inner nut and using wrench 606435 nut while tighten the adjusting slowly revolving the hub until all end-float is removed men back-off the nut approximately half a turn and retighten the nut to 13-15 in lb which will automatically allow for compression of the rubber on the new seal track spacer giving the required hub end-float of 0. Carefully fit the seal track spacer. squarely on the hub and using the 76 mm end of seal replacer tool LST550-5 and drift 550 or 18Cl34.004 in ). 23. 25. Place the seal. Although the new seal is already pre-greased by the manufacturer. This is important since a dry seal can be destroyed during the first few revolutions of the hub. drive the seal into position to the depth determined by the tool. NOTE: Instruction 28 is applicable to hubs that have been fitted with new components throughout. . : .0005 to 0. 1 27. Carry out instructions 17 to 19. If the rubber on the seal track spacer ‘has previously been compressed the hub end-float can be checked by mouting a dial indicator and bracket on the hub so that the trace pin rests in a preloaded condition on the nut. ’ . 20. 1987 FRONT AXLE & FINAL DRIVE [!$i 19. apply one of the recommended hub bearing greases to the outside diameter of the seal before fitting. Taking care not to damage the seal lips fit the hub assembly to the stub axle. chamfered side leading. lip side leading. Place the seal. 22. 26. 28. 24. Therefore hold the hub clear of the stub axle until the seal track spacer is fitted. . Do not allow the weight of the hub to rest even temporarily on the outer seal otherwise damage and distortion could occur.013 to 0. Fit the new outer bearing cone and pack with one of the recommended hub greases..- 21. 88 Continued-’ 5 ‘. REVISED: APR.R”%. lip side leading. squarely on the hub and using the 72 mm end of seal replacer tool LST550-5 and drift 550 or 186134. Fitting hub to stub axle . 29. End-float must fall within the limits given in the previous instruction. Coat the lips of both seals with one of the recommended greases.

and one bolt. ‘.1987 KANbt ROVER 30. I . . If original components have been refitted rotate the hub several times to settle the bearings then recheck the end-float. 35. in the swivel pin housing. CONSTANT VELOCITY JOINT AND SWIVEL PIN ASSEMBLY I Removing hub assembly. jack-up the vehicle.’ : ‘\ OVERHAUL STUB AXLE. 31.’ REVISED: APR. remove the axle stands. behind the shield. Disconnect the drag-link ball joint. Remove the brake disc shield secured by one nut and bolt at the bottom front. 32. AXLE SHAFT. Drain the swivel pin housing and refit plug.-. 88 1 . stub axle and joint washer. Remove the hub complete as described in the hub assembly overhaul operation instructions 1 to 7. diametrically opposite. Fit a new lock washer and iocknut. refer to previous instruction 29. Disconnect the tie-rod end ball joint from the swivel pin housing.:‘! ‘. Fit the swivel housing top bolt and brake hose bracket and tighten to the specified torque (see section 06-Torque values).’ I 31 6. AR97684 33. Using a new gasket. over the locknut. fit the hub driving shaft and evenly tighten the retaining bolts to the specified t o r q u e ( s e e s e c t i o n 06-Torque values). Remove the six bolts retaining the stub axle to the swivel pin housing. tighten the outer lock nut to 70 to 80 ft lb (95 to 108 Nm). Bend one segment of the lock washer over the adjusting nut and another. Fit the road wheels. constant velocity joint and axle shaft.. lower the vehicle to the ground and tighten the road wheel nuts evenly to the specified torque (see section 06-Torque values). Remove the mud shield. stub axle. 32 ‘\ .’ 6 . 7. Fit the brake caliper and secure with the retaining bolts and tighten to the specified torque (see section 06-Torque vaiues). 34. 36. Restraining the inner adjustment nut.

‘. Remove the spacer from the axle shaft and then the axle shaft from the axle tube. :.:. inner and outer race and the cage to ensure correct re-assembly.’ . RR2076M \ REVISED: JULY 88 .’ ‘.’ 9. . Foe. Remove the phosphor bronze bush from the axle shaft. : ‘. 12..:. Tilt and swivel the cage and inner race to remove the ball bearings. 1987 FRONT AXLE & FINAL DRIVE 8. : RR207SM . Remove the constant velocity joint from the axle shaft.... Mark -the relative positions of the constant velocity joint. . Dismantling the constant velocity joint 11. Continued 10.

Removing the swivel pin housing assembly 21. retaining plate and joint washer.025 in).1987 KANbt ROVER FRONT AXLE & FINAL DRIVE Overhaul of stub axle .. Remove the two bolts. Tapping the small protruding lug remove the lower swivel pin and joint washer. Clean and examine the stub axle.. 15. Release the assembly from the swivel pin housing. Remove the two bolts retaining the brake hose bracket and top swivel pin. Maximum acceptable end-float on the assembled joint 0. . top swivel pin and shims. 18. Remove the phosphor bronze bush using a suitable hammer and drift. :.64mm (0.. and lower swivel pin to the housing. ensuring that the inner and outer race marks are aligned during assembly.. Remove the brake hose bracket. 14. 19. .. RR207BM 13. Withdraw the cage. 8 22. the oil seal and retaining plate must remain until the swivel bearing housing is removed. To assemble the constant velocity joint reverse the dismantling instructions and lubricate with a recommended oil. and withdraw the inner race. NOTE: While the joint washer can be removed at this stage. 23. cage balls and bearing surfaces of the constant velocity joint for damage and excessive wear. Examine all components for general condition and examine the inner and outer track. . : . REVISED: JULY 88 : . 27. Remove the brake disc shield bracket. Remove the swivel pin housing while retrieving the lower and upper tapered roller bearings. remove the drain and level plugs and lock-stop bolt and nut. Using a suitable block. 28. In particular check that the inner seal track diameter is smooth and free from blemishes. 25.. 20. press or drive-in a new bush up to the shoulder of the stub axle._. Swivel the cage into line with the axis of the joint until the two opposite windows coincide with the two lands of the joint housing. 24. retaining the brake disc shield bracket. 16. Remove the seven bolts securing the swivel pin housing oil seal. 26.‘. . 17. If the swivel pin housing is to be replaced. Turn the inner track at right angles to the cage with two of the lands opposite the cage openings.

Lower swivel pin 11.’ REVISED: JULY 88 9 . Coat the swivel bearing housing to axle casing. 33. !’ --. Top swivel pin and brake hose bracket 3. i.. Using a suitable toolseat the upper and lower bearing tracks into the swivel bearing housing. Brake disc mudshield bracket 12. 37. Reassembling the swivel pin housing assembly RRBBOM Ir 11 KEY TO SWIVEL ASSEMBLY 1. Fit and secure the swivel bearing housing to the axle flange with the seven bolts tightening evenly to the specified torque (see section 06-Torque values). Place the swivel pin housing cover plate joint washer and oil seal over the axle flange ready for assembly. Using a suitable drift ease the lower bearing track out of the swivel bearing housing.. fit a new housing. 42. .. Upper and lower swivel pin bearings 4.t+ \. 1987 FRONT AXLE & FINAL DRIVE r 54 . 31. Swivel bearing housing inner oil seal 38.. 40. NOTE: Use the upper bearing opening for the drift to gain access to the lower bearing track. 36.%. Swivel bearing housing 9. pitted or damaged. Drive out the top bearing track from the swivel bearing housing. _-. NOTE: Use the lower bearing opening for the drift to gain access to the upper bearing track. NOTE: Ensure the bearing tracks are fitted square or damage could occur. 35.‘( / . 41. Swivel pin housing 2. Remove the seven bolts retaining the swivel bearing housing to the axle case. Coat both sides of the joint washer with a sealing compound and place in position on the swivel bearing housing to axle mating face. bolts with Loctite 270. 32. Remove the bolts from the housing. 6 30. joint washer 10. Swivel pin housing-oil seal plate and washer 6.’ . Oil seal 7. . Shim 5. . also grease the lips. 39.. 34. Continued .. With the seal lips trailing press the axle shaft oil seal into the rear of the housing. If worn.’ :. Joint washer 8.l Overhaul of swivel bearing housing 29. Grease and fit the upper and lower swivel pin taper roller bearings to the swivel bearing housing. Pry out the oil seal from the back of the housing also remove the joint washer and discard both.. Bolt the swivel bearing housing onto the axle case with the upper bearing track located at the bottom.

. Fit the constant velocity bearing journal into the phosphor bronze bush at the rear of the stub axle. 48. Fit the brake disc shield. ensuring that the constant velocity bearing journal engages fully into the phosphor bronze bush.i 64.35 litres (0. . adjust by removing or adding shims to the top swivel pin as required. Place the mudshield onto the stub axle and >ecurc to the swivel pin housing with the six t)ol~~ using Loctite 270. NOTE: New hub seals should be used on reassembly. 57. To check the top swivel pin pre-load. ::_: . - 1 . attach a spring balance to the track-rod and ball joint bore and pull the balance to determine the effort required to turn the swivel pin housing. and bend over the tabs of the locking washer. Set the steering lock-stop bolts to provide a minimum clearance of 20 mm (0. ensuring the splines are engaged push the shaft home. Fit the spacer onto the axle shaft. REVISED: JULY 88 : .’ . 61. 52. 66. 44. Fit the tie-rod and drag link and secure with new cotter pins. Coat the threads of the two lower swivel pm bolts with Loctite 270.’ : ” . When the correct setting has been achieved undo the bolts.“. ::. stub axle and axle shaft reassembly 56. 46. If necessary. 58. . 10 i 62.46 kg (2. . (See Section 06 Torque Values) 54. P l a c e t h e j o i n t w a s h e r i n p o s i t i o n o n t h e swivel pin housing to stub axle mating surface. 1 CAUTION: When inserting the axle shaft care should be taken not to damage the oil seal. Fit a new phosphor bronze bush onto the axle shaft.-! ! Constant velocity. . ‘. 51. Loosely fit the lock stop bolt and nut for later adjustment. . where applicable. Place axle shaft into axle tube. ‘.2 lb). 59. once the initial inertia has been overcome. 65. Secure the oil seal. Evenly tighten to the 51~~ Itled t o r q u e ( s e e S e c t i o n OC-Torque 1dlIW\ j 63 10 ’ 1 )mplete the reassembly see instructions : I 1111t1 covering front hub overhaul. CherL that the swivel pin housing drain plug is tlghrl\ tltted and remove the filler/level plug..5 to 4. lnlect approximately 0. 60.6 pints) of recommended oil or until the oil reaches the filler level hole. Fit and tighten the plug and wipe away any surplus oil. RR982M .Og of recommended grease between the lips of the swivel oil seal. Fit the brake disc shield bracket and secure with the two bolts to* the specified torque (see Section 06) and bend over the lock tabs of the mudshield bracket.6 to 3.1987 nANb= ROVER FRONT AXLE & FINAL DRIVE 43. Fit the stub axle with the machined flat on the splines in the 12 o’clock position. Fit the top swivel pin with existing shims and brake hose bracket onto the swivel pin housing. Fit the lower swivel pin with the lug outboard to the swivel pin housing.Torque values). :.. should be 1. 55. :. securing with the two bolts and locking washers. Place the swivel pin housing in position over the swivel bearing housing. Liberally apply (but do not pack) 2. (DO NOT tighten the bolts at this stage).. joint washer and cover plate with the seven bolts and spring washers to the specified torque (see Section 06-Torque values). (DO NOT tighten the bolts at this stage). coat the threads with Loctite 270 and retighten the bolts to the specified torque (see Section 06-Torque values). CAUTION: Damage to this bush can occur if this precaution is not observed. Tighten the locknut. 50.787 in) between the tyre wall and radius arm. 4i. Tighten the top swivel pin bolts to the s p e c i f i e d t o r q u e ( s e e S e c t i o n 06.16 to 1. Coat a joint washer on both sides with a sealing compound and place in position on the lower swivel pin. Tighten to the specified tourque. 53. 45. 49. The resistance.

Should more studs be unserviceable a new hub with studs must be obtained. Remove t h e b r a k e c a l i p e r . 11. 8. Drift out the grease seal and inner bearing from the hub and discard the seal.. Dial gauge bracket RO 530106. 9. Remove the locknut and tab washer. 10. jack up the vehicle and lower onto axle stands and remove the road wheel. Drive member joint washer.. D&e member retaining bolt (five off) Lock nut. 2. 6. 16. W A R N I N G: A maximum of two road wheel retaining studs can be renewed. . Dust cap. Grease seal. 15. 2. Slacken the front wheel nuts. 3. for reassembly. 12. 13. 14. 1. 15.:. Drive member. Remove the five bolts and separate the hub from the brake disc.:. if original hub is to be refitted. Outer bearing. 7. 1. 4. S e e B R A K E S section. Drive shaft shim.. 5. the relationship between the hub and brake disc. 3. 11. 9. Drift 18C 134. 5. Brake disc (vented). Remove the circlip and drive shaft shim from the drive shaft.t: 1990 FRONT AXLE & FINAL DRIVE hii F R O N T H U B A S S E M B L Y O N V E H I C L E S FllTED W I T H A N T I . Hub adjusting nut. Bend back the lock washer tab.R”. Remove the keyed washer.g 1. Inner bearing. Remove the outer bearing. 6. Mark. Withdraw the hub and brake disc assembly complete with bearings. 4.:. Hub. Disc retaining bolt (five off). 89 11 ‘. 10. REMOVE.. Keyed washer.L O C K B R A K E S (ABS) Service tools: Hub oil seal replacer LST 137. 13. KEY TO HUB ASSEMBLY 3. Drive shaft circlip. Remove the hub adjusting nut. 14. Lock washer.1 . 7. OVERHAUL AND REFIT Remove 1. Remove the five bolts and withdraw the driving member and joint washer. Drift out the inner and outer bearing tracks. ADDITION: SEPT. 8. 12. Lever off the dust cap.

28. 24.05 mm (0.p l a y o f 0 . 20. With the lip side leading fit a new seal to the hub using special tool LST 137 seal replacer and drift 18C 134. Mount a dial gauge using bracket RO 530106 and rest the stylus in a loaded condition on the adjusting nut. 18G. . 26. 89 :. Fit the original drive shaft shim and secure with a circlip. Applying Loctite 270. Assemble the brake disc to the hub.0005 to 0.134 LST RR2771 M RO 530106 25. 23. . 29. Fit the keyed washer. 21.-. Pack the hub inner bearing with a recommended grease and fit to the hub. Drive in the seal so that it is flush with the rear face of the hub. RR2767M 17. 19. 27. Fit a new keyed lock tab washer. lining up to the marks made during dismantling. Fit a new joint washer to the driving member and fit the member to the hub and secure with the five bolts tightening evenly to the correct torque. / 12 ADDITION: SEPT. Fit and tighten the hub adjusting nut and recheck the end-play before bending the lock tab over. Clean the stub axle and drive shaft and fit the hub assembly to the axle.. 0 1 3 t o 0. Fit the hub adjusting nut and tighten by hand whilst rotating the hub until all end-play is taken up. Slacken off the adjusting nut until a hub e n d . 22. Grease as in instruction 17 and fit the outer bearing to the hub. fit and tighten the five retaining bolts to the correct torque.1990 KANGe ROVER Refit 16. 18. Apply grease between the seal lips.002 in) is obtained. Clean and degrease the hub and drift in the inner and outer bearing tracks. .

: ‘. To check the drive shaft end-play mount a dial gauge using bracket RO 530106 and rest the stylus in a loaded condition on the end of the drive shaft. 2. measure the shim thickness and fit an appropriate shim to give the required end-play. . . Refitting 4. Fit the road wheel. Fit a suitable bolt to the threaded end of the drive shaft and using a pair of pliers move the drive shaft back and forth noting the dial gauge reading. If the end-play requires adjustment.25 mm (0. _.. 34. 6. 31. 7. . . Material may be machined off the disc faces.. remove the circlip.15 mm (0. this must not exceed 0. .006 in).. 3. Remove the front hub assembly. . .:::. Locate the disc on to the hub. Remove the bolt from the drive shaft. 33. see ABS brake bleed procedure. Disc reclamation Check the vented disc thickness. Fit the brake caliper. ADDITION: SEPT. see BRAKES section. Apply Loctite 270 and fit the hub to disc retaining bolts. remove the axle stands and finally tighten the road wheel nuts. 89 13 ‘. If necessary reposition the disc. REFIT AND RECLAIM Removing 1. Tighten to the correct torque. FRONT DISCS ON VEHICLES Fill-ED WITH ABS REMOVE.:I. . 35. .866 in). This dimension may be reduced to a minimum thickness of 22 mm (0. 37.010 in)..08 to 0. 5. fit the circlip and dust cap.i : _.. Operate the footbrake several times to locate the brake pads before taking the vehicle on the road. .FRONT AXLE & FINAL DRIVE 30. The end-play should be between 0. Tap off the disc from the hub.003 to 0. Remove the five hub to disc retaining bolts. On completion equal thicknesses of disc must remain each side of the vent. . 36.- 32. check the total disc runout.: ‘. Fit the hub assembly. Using a dial indicator. Bleed the brake system. .

Remove the stub axle and joint washer. Mark the relative positions of the constant velocity joint inner and outer race and the cage for correct reassembly. Remove the circlip and collar from the axle shaft. Using a soft mallet drive the constant velocity joint from the shaft.: ADDITION: SEPT. 11. Remove the six bolts retaining the stub axle to the swivel housing..‘..OVERHAUL FRONT STUB AXLE. . Drain the swivel pin housing and refit plug. : : 6. RR 2783M \ 1.. Remove the hub complete as described in the operation to overhaul the hub assembly on ABS fitted vehicles. 4. Tilt and swivel the cage and inner race to remove the balls. Remove constant velocity joint from axle shaft 7. I . Remove the mud shield.CONSTANT VELOCITY JOINT AND SWIVEL ASSEMBLY ON VEHICLES FllTED WITH ABS Service tools: 18C 284AAH extractor. 3. I I 1.i .. . ‘1 . Hold the axle shaft firmly in a soft jawed vice. 8.1.. ST1 025M . LST 132 bearing installer. . Dismantle the constant velocity joint 10. 9. Pull out the axle shaft and constant velocity joint from the axle casing. /--A Remove stub axle. axle shaft and constant velocity joint. 5.‘~. 2. 89 . LST 133 seal installer. : ‘...’ 14 1..

drive the joint home. Remove the bearing and oil seal using special tool 18C 284AAH and slide hammer. 20. Engage the constant velocity joint on the axle shaft splines and using a soft mallet.FRONT AXLE & FINAL DRIVE 12. ADDITION: SEPT. and instructions the dismantling reverse lubricate with a recommended oil. Ensure that the fingers of the tool locate behind the bearing to drive it out. Check that the end-float of the assembled joint does not exceed 0.thrust ring. cage balls and bearing surfaces of the constant velocity joint for damage and excessive wear. Fit the collar and a new circlip. 18. 16. 90 15 . Drill and chisel off the thrust ring taking care to avoid damaging the stub axle.025 in). Repeat for the oil seal. Examine the inner and outer track. 89/REVISED:SEPT. oil seal and bearing 21. 22.64 mm (0. 17 T o a s s e m b l e t h e c o n s t a n t v e l o c i t y j o i n t . 18G284 AAH ST1026M 15 Degrease and examine all components for general wear and condition. 13. Turn the inner track at right angles to the cage with two of the lands opposite the cage openings and withdraw the inner race. Swivel the cage into line with the axis of the joint and turn it until two opposite windows coincide with two lands of the joint housing. Fit constant velocity joint to axle 19. Withdraw the cage. I Renew stub axle. 14.

42. . 40. . Withdraw the top swivel pin and shims. From 1991 model year.‘. Disconnect the drag-link ball joint. 30. fit bearing with its part number visible when fitted. Remove the swivel pin housing while retrieving the lower taper bearing. Press out the top swivel pin bush housing assembly. If the swivel pin housing is to be renewed. 90 ‘.. Prise the seal irom the swivel pin housing. 28. Discard the thrust washer. Disconnect the jump hoses from the brake jump hose bracket. level and filler plugs and lock-stop bolt. . Drift out the lower swivel pin bearing track. renew the swivel pin bearing housing. . 41. 37. Press fit a new thrust ring onto the stub axle 16 ADDITION: SEPT. If worn. Remove swivel pin housing. RR2760M .: 24. 25. Remove and overhaul swivel pin bearing housing 38. 31. 33. 35. and the lower swivel pin to the housing. Disconect the track-rod end ball joint from the housing. 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 t washer by tapping the small protruding lug. Press in a new lower swivel pin bearing track. RR2761M . R e m o v e t h e b r a k e s h i e l d s e c u r e d a t t h e bottom by one nut and bolt. Remove the two countersunk screws securing the brake damper/shield bracket. Remove the swivel pin bearing housing. and flush with the end face of the stub axle.. Remove the ABS brake sensor. 39. Refit 23.. IJIREVISED: i SEPT. 34. 32. 19. Using special tool LST 132. 27. 36. Remove the top swivel pin retaining bolts complete with the brake jump hose bracket. 1990 ROVER KANClt FRONT AXLE & FINAL DRIVE . LST133 ---I 23 26... NOTE: The oil seal and retaining plate cannot be removed until the swivel pin bearing housing is removed. 43.’ . Lubricate the seal and lip with EP90 oil and with the cavity side leading press in a new oil seal using special tool LST 133. discard the thrust washers and bearing. and midway by the lock stop nut. the drain. pitted or damaged. . Remove and discard the oil seal and joint washer. Remove the six bolts securing the oil seal and retaining plate to the swivel pin housing. Remove the seven bolts securing the swivel pin bearing housing to the axle case.. .

‘. Ensure that the relieved lip of the bush housing faces towards the rear oil seal. as shown.lbs). Check it is in position when fitting the top swivel pin. lip side leading to the top swivel pin. and reading from the centre of the swivel assembly from lock to lock to be 2. “L RR2983M Fit remaining components 59.007 to 0. 52. Check and adjust preload on bearings 1990 model year 57 The preload on bearings to be 0. 54.T. 60.. together with the damper and shield bracket. ‘. . Adjust by removing or adding shims to the top swivel pin. Grease the lips. without the swivel housing oil seal and axle fitted.>:.. Check and adjust preload on bearings 1991 model year on : 45.. 57 ‘ Fit swivel pin housing .18 to 0. 46.8 Nm (18 to 25 in. Using a new joint washer.g 1990 FRONT AXLE & FINAL DRIVE r 54 l 44.. Do not secure with screws at this stage. / u . 58 To take a reading use special tool LST 141 torque test adaptor.F. Fit a new joint washer and secure the swivel pin bearing housing to the axle.:’7 . 48.30 mm (0.009 ins).. With the seal lips trailing press the axle shaft oil seal flush into the rear of the housing.25 to 0. assembly order. and reading from the centre of the swivel pin.010 to 0. The preload on bearings to be 0. Secure the oil seal with the retaining plate and securing bolts tightening evenly to the correct torque. Place the swivel pin housing in position over the swivel pin bearing housing. Tighten the top swivel pin and brake jump hose bracket securing bolts to the correct torque.012 ins).E. 50. 55. with a torque wrench and extension as shown. Fit a new thrust washer into the top swivel pin with the black P. Press in a new bush and bush housing.23 mm (0.po. 47.3 Nm (45 to 65 in. Coat the threads of the top swivel pin bolts with Loctite 542.1 to 7. 51. C o a t t h e t h r e a d s o f t h e l o w e r s w i v e l p i n screws with Loctite 270 and fit. Fit a new sensor bush and new oil seal. 56.lbs). fit the lower swivel pin with lip outboard. Grease and fit the lower swivel pin bearing to the bearing housing. Tighten evenly to the correct torque. ‘_. Hang the swivel pin bearing housing oil seal and retainer plate over the back of the Ensure they are in the correct housing. Adjust by removing or adding shims to the top swivel pin. Fit the bolts and jump hose bracket (do not tighten). Starting with the top fixing dowel bolt. 53. Lubricate with a recommended oil and fit the top swivel pin with existing shims..0 to 2. 49. ADDITION: SEPT. 90 17 .. without the swivel housing oil seal and axle fitted. . Tighten to the correct torque. bush coating uppermost. . From 1991 model year fit new thrust washers and thrust bearing. The torque required to turn the swivel assembly from lock to lock to be 5.. 89/REVISED: SEPT. Liberally apply (do not pack) a recommended grease between the lips of the swivel housing oil seal.

seal. 12. 27. 8. Oil seal. 3. C. Brake caliper. 25. Joint washer. 16. 11. Damper and shield bracket. 9. 14. Stub axle. 4. Bearing. Lower swivel pin bearing. Swivel pin housing. joint washer. joint. 7. Inner drive shaft. 24. Mud shield. 5. Oil . Thrust washer. 23. 16 . RR2936M - 15. 21. 10. 20. Thrust bearing. Swivel pin bearing housing. Bush and housing. feint washer.V. Brake disc shield. Bush. Oil seal. 13. Top swivel pin and jump hose bracket. 1991 model year. 19. 18. 22. Lower swivel pin. 2. 26. 6. Oil seal retaining plate. 17. Circlip. 28. Sensor bush. Shim.KEY TO DRIVE SHAFT AND SWIVEL ASSEMBLY 1.

66. 71. Coat the threads of the stub axle bolts with Loctite 270.787in) between the tyre wall and radius arm. ADDITION: SEPT. 65. Tighten the locknut which also secures the brake disc shield. 73. and when the differential splines are engaged. To complete the assembly. Fit and tighten the filler and level plugs and wipe away any surplus oil. 69. 63. Place the mud shield in position and secure the stub axle to the swivel pin housing with the six bolts and tighten evenly to the correct torque. Loosely fit the lock stop bolt for later adjustment. Before the stub axle is secured.89 . Fit the track-rod and drag link and secure with new split pins.6 pints) of recommended oil until the oil reaches the level hole. 70.F . Set the steering lock-stop bolt to provide a clearance of 20mm (0. Leaving the middle fixing nut loose until the lock stop has been set. 72._ ” 67. Fit the brake disc shield. CAUTION: Take care not to damage the axle shaft oil seals. Inject approximately 0. Check that the swivel pin housing oil drain plug is tightly fitted and remove the filler and level plugs. CAUTION: Ensure that the constant velocity joint bearing journal is butted against the thrust ring on the stub axle. Place a new joint washer in position on the swivel pin housing to stub axle mating face. Fit the stub axle with the keyway at the I2 o’clock position. Fit the ABS brake sensor following the instructions in the brake section. Fit the brake jump hoses to the brake jump hose bracket. 68.FRONT AXLE & FINAL DRIVE 61. follow instructions to fit front hub on ABS fitted vehicles. push the assembly home.35 litres (0. . 62. Fit drive shaft and stub axle 64. Insert the axle shaft.

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