Content .. 84 85 86 87 ..

Range Rover Classic. Manual - part 86

REAR AXLE AND FINAL DRIVE

OVERHAUL

12. Remove pinion head bearing with service tool

LRT-99-002.

13. Remove bolts and washers securing crown

wheel to differential flange. Remove crown
wheel.

14. Remove differential carrier bearings.
15. Remove circlips and extract differential cross

shaft.

16. Withdraw differential gears and pinions.
17. Clean all components.

INSPECTION

18. Check all bearings for wear and pitting.
19. Check all gears for wear, scuffing, pitting and

damaged teeth.

20. Supplied as matched sets are: crown wheel and

pinion, pinion housing and bearing caps.

ASSEMBLE

Differential gears

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

REAR AXLE AND FINAL DRIVE

OVERHAUL

23. Check gear for freedom of rotation and backlash.

Nominal backlash should be present. Excess
backlash necessitates replacement of gears or
differential housing.

24. Check serial number marked on pinion end face

matches that on crown wheel.

25. Clean and fit crown wheel.
26. Fit carrier bearings and assemble tracks to

bearings.

27. Place differential housing with crown wheel and

bearings in pinion housing.

28. Fit bearing caps and bolts. Do not tighten bolts.
29. Fit bearing adjusting nuts and adjust to obtain

zero end float.

30. Tighten bearing cap bolts to

90 Nm.

31. Check crown wheel for run-out. This should not

exceed 0,10 mm. If exceeded examine crown
wheel and mounting flange for burrs, grit, etc.
Refit and recheck. A buckled or damaged
differential housing flange is corrected by
replacing differential gear housing.

32. After checking run out remove differential

housing from pinion housing.

33. Remove crown wheel bolts and refit using

Loctite ’Studlock’. Tighten to

58 Nm.

34. Fit pinion head bearing track and original shim to

pinion housing. Use service tools LRT-54-505
and LRT-54-506. If fitting a new shim use
minimum 1.27 mm thickness.

REAR AXLE AND FINAL DRIVE

OVERHAUL

35. Fit pinion outer bearing track to pinion housing.

Use service tools LRT-54-505 and LRT-54-507.

36. Fit pinion head bearing to pinion. Use service

tool LRT-54-502.

37. Fit pinion into its location without shims for

bearing pre-load.

38. Fit outer bearing, and spacer (front axle

differential only).

39. Fit driving flange, washer and nut.

40. Do not fit oil seal at this stage.
41. Tighten pinion flange nut until force required to

rotate pinion is

3 Nm if new bearings are fitted.

This will pre-load bearings to check pinion height
dimension.

NOTE: If using original bearings, pre-load
figure is 1.5 Nm.

Drive pinion markings

NOTE: Markings on end face adjacent to
serial number are of no relevance to
servicing.

42. Figures marked on end face opposite to serial

number show in thousandths of an inch,
deviation from nominal, required to set pinion.
Pinions marked plus (+) must be set below
nominal. Pinions marked minus (-) must be set
above nominal. Unmarked pinions must be set at
nominal.

REAR AXLE AND FINAL DRIVE

OVERHAUL

43. Nominal setting dimension is represented by

setting gauge block LRT-54-503. Referenced
from pinion end face to bottom radius of
differential bearing bore.

Drive pinion adjustment

44. Ensure pinion end face is free of burrs around

etched markings.

45. Remove keep disc from magnetized base of dial

gauge tool.

46. Place dial gauge and setting block on surface

plate. Zero dial gauge trace pin on setting block.

NOTE: Setting block has three height
settings heights.

Use 39.50mm setting mark for this differential.

Pinion height shims

PART No.

INCH

FTC3853

.061

1.548

FTC3854

.060

1.523

FTC3855

.059

1.498

FTC3856

.058

1.473

FTC3857

.057

1.448

FTC3858

.056

1.423

FTC3859

.055

1.398

FTC3860

.054

1.373

FTC3861

.053

1.348

FTC3862

.052

1.323

FTC3863

.051

1.298

FTC3864

.050

1.273

FTC3865

.049

1.248

FTC3866

.048

1.223

FTC3867

.047

1.198

FTC3868

.046

1.173

47. Position dial gauge centrally on pinion end face,

Content .. 84 85 86 87 ..