LEMON Manuals: Even more car manuals for everyone
Home >> Land Rover >> 2000 >> Discovery >> Repair and Diagnosis >> Transmission >> Overhaul - Transfer Case >> Overhaul >> Differential Assembly >> Installation

Differential Assembly: Installation

  1. Clean differential components. Remove all traces of sealant from housings and bolts, differential lock warning lamp switches and detent plugs.
  2. Lubricate components with transfer box oil.
  3. Position differential in soft jawed vice and fit front bearing using tool LRT-41-008. See Fig 1 .
  4. Invert differential in soft jawed vice, and fit low range gear with dog teeth facing uppermost. See Fig 2 .
  5. Fit high/low hub ensuring that machined groove on hub teeth faces towards low range gear. See Fig 2 .
  6. Fit high/low selector sleeve ensuring that alignment marks on hub and sleeve are together. See Fig 2 .
  7. Fit bush to high range gear ensuring collar is uppermost. See Fig 2 .
  8. Fit high range gear and bush onto shaft. See Fig 2 .
  9. Fit NEW rear bearing using tool LRT-41-008. See Fig 3 .
    10. CAUTION: Ensure that threads of replacement nut are PATCHED. Patched nuts have a locking agent pre-applied to the threads. They are identified by the presence of a colored section of thread which extends for up to 180 degrees around the thread.
  10. Using tool LRT-41-007, fit NEW bearing retaining nut and tighten to 72 N.m (53 ft. lbs.). DO NOT stake nut at this stage. See Fig 4 .
  11. Using feeler gauges, determine clearance between low range gear and high/low hub. See Fig 5 :
    • Clearance = 0.0-0.15 mm (0.002-0.006").
  12. If clearance is not as specified, fit a NEW low range gear and high/low hub and re-check.
  13. Using feeler gauges, determine clearance between high range gear and high/low hub. See Fig 6 :
    • Clearance = 0.05-0.15 mm (0.002-0.006").
  14. If clearance is not as specified, fit NEW high range gear and high/low hub and re-check.
  15. Using a suitable drift, stake collar of nut into differential shaft recess.
  16. Using LRT-51-009, fit NEW rear bearing track into main casing. See Fig 7 .
  17. Using a straight edge and feeler gauges, check that bearing track is recessed 1 mm (0.04") below outer face of main casing.
  18. Apply sealant, Part No. STC 4600 to rear output shaft housing face.
  19. Position housing to main casing.
  20. Apply sealant, Part No. STC 50552 to bolt threads fit housing to main case, fit bolts and tighten by diagonal selection to 45 N.m (33 ft. lbs.).
    21. CAUTION: Ensure ends of spring are fully seated in recess in clips.
  21. On 2003 Model Year onwards, fit high/low selector fork and spring to high/low selector shaft, fit retaining clips.
  22. Position high/low selector shaft and fork to differential ensuring that fingers of selector fork are located in selector sleeve.
  23. Position differential assembly into main casing ensuring that splines of rear output shaft are engaged in differential.
  24. Position NEW differential front bearing track ensuring that track is seated squarely.
  25. Position tool LRT-41-014/3 onto main casing. See Fig 8 .
  26. Screw tool LRT-41-014/4 into tapped hole in main casing and attach suitable Dial Test Indicator (DTI) to pillar. See Fig 8 .
  27. Position stylus of gauge to setting block LRT-41-014/3 and zero gauge. See Fig 8 .
  28. Position stylus onto front bearing outer track and record reading. See Fig 9 .
  29. Taking care not to disturb bearing, position stylus on opposite side of bearing track and record reading.
  30. Obtain average of the 2 readings and record figure.
  31. Position depth block tool LRT-41-014/2 and cross bar tool LRT-41-014/1 to front output housing. See Fig 10 .
  32. Position DTI to tool LRT-41-014/1 cross bar and zero Dial Test Indicator (DTI) on depth block.
  33. Position DTI to cross bar and record reading obtained.
  34. Using the formula - 3.05 mm (0.120") + B - A = D, where:
    • A = Average of readings to differential front bearing outer track.
    • B = Height difference recorded between depth block and cross bar.
    • D = Thickness of shim required to give differential bearing pre-load of 0.05 mm (0.002").
  35. From the resultant figure obtained, select appropriate thickness shim from the range available.
  36. Shims are available from 2.00-3.25 mm (0.08-0.13") thickness, rising in increments of 0.05 mm (0.002").
  37. Heat the front output housing to 100°C (212°F) and fit NEW output shaft bearing using tool LRT-41-011. See Fig 11 .
  38. Allow housing to air cool.
  39. Fit NEW bearing retaining circlip ensuring that circlip is fully seated.
    40. CAUTION: Oil seal must be fitted dry.
  40. Using tool LRT-41-012, fit NEW output shaft oil seal. Check that oil seal is just contacting circlip. See Fig 12 .
  41. Position selected shim in front output housing and using tool LRT-54-003, fit NEW differential front bearing track. See Fig 13 .
  42. Fit bearing spacer to output shaft with chamfer on spacer towards threaded end. See Fig 14 .
  43. If fitted, fit dog clutch with flange on clutch facing towards splined end. See Fig 14 .
  44. Using a copper mallet, drive output shaft into bearing. If not fitted with differential lock, go to step
    45. NOTE: Carry out the following operations for transfer boxes fitted with differential lock.
  45. Compress differential lock selector spring and fit selector fork.
  46. Position selector fork to groove in dog clutch.
  47. Fit selector shaft and locate in housing recess, rotate shaft until the two flats for retaining clips are at right angles to the cover plate mating face.
    48. CAUTION: Ensure ends of spring are fully seated in recess of clips.
  48. Compress selector spring and fit retaining clips at each end of spring.
  49. Apply sealant, Part No. STC 4600 to front output shaft housing.
  50. Position front output shaft housing ensuring that output shaft and dog clutch splines, if fitted, are correctly engaged.
  51. Clean output shaft housing bolt threads.
  52. Apply sealant, Part No. STC 50552 to threads of bolts.
  53. Fit output shaft housing bolts and tighten in a diagonal sequence to 45 N.m (33 ft. lbs.).
  54. Apply sealant, Part No. STC 4600 to mating face of high/low selector housing.
  55. Position high/low selector housing to front output housing ensuring that high/low selector finger is located in groove in selector shaft.
  56. On 2003 Model Year onwards, position multiplug and selector cable brackets to high/low selector housing.
  57. Apply sealant, Part No. STC 50552 to threads of selector housing bolts.
  58. Up to 2003 Model Year, fit bolts and tighten to 25 N.m (18 ft. lbs.).
  59. Fit differential lock detent ball and spring.
  60. Apply sealant, Part No. STC 50552 to threads of differential lock detent plug.
  61. On 2003 Model Year onwards with differential lock, fit and tighten detent plug, then loosen 2 complete turns.
  62. On 2003 Model Year onwards with differential lock, apply sealant, Part No. STC 50552 to threads of differential lock detent plug.
  63. On 2003 Model Year onwards with differential lock, fit detent ball and spring.
  64. On 2003 Model Year onwards with differential lock, fit differential lock detent plug and tighten until head of plug is level with face of output shaft housing. See Fig 15 .
  65. On 2003 Model Year onwards with differential lock, using a straight edge, check that head of plug is correctly positioned, screw plug in or out as necessary. See Fig 15 .
  66. On 2003 Model Year onwards with differential lock, lubricate and fit NEW "O" rings to differential lock selector housing.
  67. On 2003 Model Year onwards with differential lock, fit selector housing, ensure selector finger is located in shaft recess.
  68. On 2003 Model Year onwards, position cable bracket to selector housing.
  69. Apply sealant, Part No. STC 50552 to threads of selector housing bolts, fit bolts and tighten to 25 N.m (18 ft. lbs.).
  70. Up to 2003 Model Year with differential lock, fit nut to differential lock warning lamp switch with counterbore positioned towards switch head. The nut acts as a spacer to ensure that switch setting is correct. Always ensure that nut is fully tightened to switch head (no gap). See Fig 16 .
  71. Apply sealant, Part No. STC 50552 to threads of differential warning lamp switch.
  72. Position switch into front output housing until nut bottoms out on housing; tighten nut to 11 N.m (8 ft. lbs.).
    73. CAUTION: Ensure that replacement washers are the same thickness as the originals.
  73. On 2003 Model Year onwards with differential lock, fit NEW aluminum sealing washers to differential lock warning lamp switches.
  74. On 2003 Model Year onwards with differential lock, apply sealant, Part No. STC 50552 to threads of switches.
  75. On 2003 Model Year onwards with differential lock, fit switches and tighten to 25 N.m (18 ft. lbs.).
  76. Fit output flange, NEW felt washer, steel washer and NEW retaining nut.
  77. Using tool LRT-51-003 to restrain flange, tighten output flange nut to 162 N.m (119 ft. lbs.). See Fig 17 .
  78. If fitted, operate differential lock selector lever and check that detent ball can be felt to positively engage/disengage with grooves in shaft.
  79. Up to 2003 Model Year with differential lock, screw plug in or out until setting is correct.
  80. Fit high/low selector shaft detent ball and spring.
  81. Apply sealant, Part No. STC 50552 to threads of high/low selector shaft detent plug.
  82. Up to 2003 Model Year with differential lock, fit and tighten plug, then loosen 2 complete turns.
  83. On 2003 Model Year onwards with differential lock, fit detent plug and tighten until head of plug is level with face of main casing. Using a straight edge, check that plug is correctly positioned; screw plug in or out as necessary. See Fig 18 .
  84. On 2003 Model Year onwards with differential lock, operate high/low selector lever and check that detent ball can be felt to positively engage/disengage with grooves in shaft.
  85. Up to 2003 Model Year with differential lock, screw plug in or out until setting is correct.
  86. Fit intermediate gear cluster. See INTERMEDIATE GEAR ASSEMBLY  .
Fig 1: Installing Front Bearing
G00368482Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 2: Installing Differential High/Low Hub, Gears & Selector Sleeve
G00368483Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 3: Installing Differential Rear Bearing
G00368484Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 4: Installing NEW Bearing Retaining Nut
G00368485Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 5: Measuring Low Range Gear & High/Low Hub Clearance
G00368486Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 6: Measuring High Range Gear & High/Low Hub Clearance
G00368487Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 7: Installing NEW Main Casing Rear Bearing Track
G00368488Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 8: Calculating Differential Bearing Pre-Load Shim Thickness (1 Of 3)
G00368489Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 9: Calculating Differential Bearing Pre-Load Shim Thickness (2 Of 3)
G00368490Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 10: Calculating Differential Bearing Pre-Load Shim Thickness (3 Of 3)
G00368491Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 11: Installing NEW Output Shaft Bearing
G00368492Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 12: Installing NEW Output Shaft Oil Seal
G00368493Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 13: Installing Shim & NEW Differential Front Bearing Track
G00368494Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 14: Installing Output Shaft Bearing Spacer & Dog Clutch
G00368495Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 15: Installing Differential Lock Output Shaft Housing Detent Plug (2003 Model Year Onwards, If Fitted)
G00368496Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 16: Installing Differential Lock Warning Lamp Switch (2003 Model Year Onwards, If Fitted)
G00368497Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 17: Installing Output Flange Nut
G00368498Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 18: Installing Differential Lock Main Casing Detent Plug (2003 Model Year Onwards, If Fitted)
G00368499Courtesy of LAND ROVER NORTH AMERICA, INC.
scientia non olet · About LEMON Manuals