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Differential Assembly: Inspection

  1. Check mating surfaces of cross shaft and housing bore for wear.
  2. Check core plug in housing for signs of leakage or corrosion. Apply sealant, Part No. STC 3811 to replacement plug.
  3. Measuring across widest portion of high/low selector finger. See Fig 1 . Check high/low selector finger for wear:
    • Finger width = 15.90 to 15.95 mm (0.625 to 0.627").
  4. Check bearing track recesses in housing for damage, rectify or replace housing as necessary.
  5. If NOT fitted with differential lock, go to step  15 . If fitted with differential lock, go to next step and carry out inspection of differential lock components using following procedures.
  6. Check differential lock selector shaft and housing bore for wear.
  7. Measuring across the widest portion, check differential lock finger for wear. See Fig 2 :
    • Finger width = 15.90 to 15.95 mm (0.625 to 0.627").
  8. Check differential lock selector finger groove in selector shaft. See Fig 3 :
    • Groove width = 16.0 to 16.1 mm (0.63 to 0.64").
  9. Check detent grooves in differential lock selector shaft for wear. See Fig 4 .
  10. Check differential lock detent ball for flat spots and check detent spring for distortion.
  11. Check differential lock selector fork for cracks and wear.
  12. Check differential lock selector fork finger width. See Fig 5 :
    • Finger width = 7.92 to 7.97 mm (0.311 to 0.313").
  13. Check differential lock selector fork clips for wear and damage. Check spring for distortion and free length:
    • Spring free length = 84.58 mm (3.33").
  14. Check dog clutch internal teeth and grooves and teeth on output shaft for wear and damage. See Fig 6 . Check selector fork groove width:
    • Groove width = 8.05 to 8.20 mm (0.32 to 0.33").
  15. Carry out the following inspection procedures for ALL transfer boxes.
  16. Check threads and splines of output shaft for damage and wear. Check dog clutch teeth on shaft for wear and damage.
  17. On 2003 Model Year onwards, compress high/low selector fork spring and remove retaining clips from each end of spring, remove high/low selector shaft. See Fig 7 .
  18. Check detent grooves in high/low selector shaft for wear. See Fig 8 . DO NOT remove fork from shaft unless either component is being renewed. If fork is removed from shaft, coat the threads of the set screw with sealant, Part No. STC 50552 prior to assembling.
  19. Check width of high/low selector groove. See Fig 8 :
    • Groove width = 16.0 to 16.1 mm (0.63 to 0.64").
  20. Check high/low selector fork for cracks and wear. See Fig 9 . Check selector fork finger width:
    • Finger width = 7.37 to 7.47 mm (0.290 to 0.294").
    21. NOTE: High/low selector shaft, fork and spring fitted to 2003 Model Year transfer boxes may be fitted to pre 2003 Model Year boxes as an assembly.
  21. On 2003 Model Year onwards, check high/low selector fork clips for wear and damage. Check spring for distortion, check free length of spring:
    • Spring free length = 75 mm (2.95").
  22. Check differential sun and planet gears for wear, cracks and chipping of teeth.
  23. Check cross shafts and recesses in both halves of differential carrier for damage and wear. ENSURE planet gears are retained with their respective shafts.
  24. Check retaining ring for distortion.
  25. Check differential splines for wear and damage.
  26. Check high/low hub for cracks, chipping and uneven wear. See Fig 10 . Check width of selector fork groove:
    • Groove width = 7.5-7.6 mm (0.295-0.30").
  27. Check splines and teeth on high/low selector sleeve for uneven wear, cracks, damage and chipping.
  28. Check teeth of high and low range gears for cracks, chipping and uneven wear.
  29. Check high range gear bush for wear and damage.
Fig 1: Measuring High/Low Selector Finger Width
G00368468Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 2: Measuring Differential Lock Finger Width
G00368469Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 3: Checking Finger Groove In Differential Lock Selector Shaft (2003 Model Year Onwards Shown)
G00368470Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 4: Checking Detent Grooves In Differential Lock Selector Shaft (2003 Model Year Onwards Shown)
G00368471Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 5: Checking Differential Lock Selector Fork
G00368472Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 6: Checking Dog Clutch For Wear & Damage
G00368473Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 7: Removing High/Low Selector Shaft (2003 Model Year Onwards)
G00368474Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 8: Checking High/Low Selector Shaft (2003 Model Year Onwards)
G00368475Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 9: Checking High/Low Selector Fork
G00368476Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 10: Checking High/Low Hub
G00368477Courtesy of LAND ROVER NORTH AMERICA, INC.
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