205-02 Rear Drive Axle Differential

http://topix.landrover.jlrext.com/topix/service/procedure/146634/OD...
Published: 23-Sep-2011
Rear Drive Axle/Differential Lubrication
Description
Lubricant
Haldex controlled coupling Statoil SL01-301. Land Rover Part No LR003136
Rear drive axle/differential Castrol Axle EPX 80W-90. Land Rover Part No LR003156
Capacity (liters/pints/US quarts)

0.65/1.1/0.69
0.7/1.2/0.74
General Specification
Item
Differential type
Ratio
Electronic torque managed (ETM) range
Specification
Low offset hypoid spiral bevel design
2.58:1
Up to 1500 Nm (1106 lbf.ft)
Torque Specifications
Description
Active on-demand coupling module
Active on-demand coupling to differential
Active on-demand oil pump
Driveshaft to the rear flange*
Rear differential front bush retaining bolts*
Rear differential insulator to the rear differential
Rear differential rear bush retaining bolts*
Rear differential support bracket
Rear drive axle/differential pinion flange nut*
Rear drive axle/differential fluid drain plug
Rear drive axle/differential fluid filler plug
* New nuts/bolts must be fitted
1 of 1
Nm
6
24
6
40
175
25
110
25
130
35
35
lb-ft
4
18
4
30
129
18
81
18
96
26
26
23/02/2012 8:02 AM
Published: 11-May-2011
Part Number
-
Rear Drive Axle/Differential - Rear Drive Axle and Differential

Description and Operation
COMPONENT LOCATION
Item
Part Number
Active on-demand coupling
Differential
Description
OVERVIEW
The differential operates in conjunction with the active on-demand coupling to provide drive to the rear axle.
Vehicles from 2009MY

Generation 4 Active On-Demand Coupling from 2009MY
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Vehicles from 2009MY are fitted with a modified design of the active on-demand coupling, known as the generation 4 unit.
The new active on-demand coupling has design improvement changes over the previous generation 3 coupling which give the
following advantages:
Reduced base torque at high differential speed
Torque activation independent of differential speed
Accurate torque limiter
Energy stored in accumulator
Lower max current consumption
Faster response.
DIFFERENTIAL
The differential unit is a low-offset-hypoid spiral-bevel design, based on a 167mm crown wheel geared to deliver a ratio of
2.58:1. The design of the differential gears and the 4 mountings that control the torque reaction of the unit within the rear
subframe, provide a differential unit of excellent efficiency and refinement.
The torque delivered to the differential is controlled by the active on-demand coupling, mounted into the void at the front of
the differential's cast-aluminum casing, which also provides the oil reservoir for the coupling.
ACTIVE ON-DEMAND COUPLING

Active On-demand Coupling
NOTE: Generation 3 coupling shown.
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Item
Description
Check valves - exhaust side
Control valve / axial solenoid
Oil pressure and temperature sensor
Input shaft
Electric hydraulic pump
Oil filter
Accumulator
Check valve - intake side
10
Combined check and by-pass valve
11
Ring shaped annular piston
12
Inner connection hub with splines for outer hub.
13
Inner and outer wet clutch plates
The active on-demand coupling provides the benefits of a permanent 4x4 system with the efficiency and economical benefits
of a part-time system. Located between the differential and driveshaft, the coupling is a self-contained unit combining
mechanical, hydraulic and electronic functions to distribute drive between the front and rear axles with transparent automatic
control.
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The active on-demand coupling provides the following functions:

Electronic management of torque transfer.
Rapid engagement in response to traction demands.
Rapid disengagement to ensure its operation cannot corrupt wheel speed signals and compromise stability control
system operation; this is especially important on very low friction surfaces.
Pre-engagement from rest to minimize the risk of wheel-spin.
No opposing forces when maneuvring or parking the vehicle.
Not sensitive to brake testing on a chassis dynamometer.
Generation 4 Active On-Demand Coupling - Vehicles from 2009MY
The generation 4 coupling does not have the differential speed driven pump used on the previous generation 3
coupling, but is fitted with a bigger capacity electrically operated axial pump and a high pressure accumulator.
The proportional throttle valve and pressure sensor on the generation 3 coupling is replaced with a proportional
pressure reducing valve.
The torque limiter pressure reducing valve on the generation 3 coupling is replaced by an electronic control valve and
controlling software.
The generation 4 active on-demand coupling gives the following improvements over the previous generation 3 coupling:
Reduced base torque at high differential speeds
Torque activation is now independent of differential speed
Accurate torque limiter control
Energy stored in high pressure accumulator giving a low maximum current consumption of the electric pump and
faster response.
Control Module - Generation 3 and 4 Couplings

The control module, attached to the casing of the active on-demand coupling, forms a single unit with the control valve/axial
solenoid. By analyzing information from other vehicle modules and sensors the control module regulates the axial solenoid to
control the hydraulic fluid pressure supplied to the clutch plates. Some of the modules and sensors the control module
communicates with are listed below:
Hardwired:
Control valve / axial solenoid
Electric hydraulic pump
Oil pressure and temperature sensor
High speed CAN (controller area network):
Engine control module
Anti-lock brake system / traction control module
Traction response switch
Yaw rate sensor
Steering wheel rotation sensor
The axial solenoid constantly adjusts the control valve output using a Pulse Width Modulation (PWM) signal. The fluid pressure
delivered to the clutch plates determines the amount of torque that is delivered to the rear axle.
The active on-demand coupling has integrated oil pressure and temperature sensors to enable the control module to
accurately manage the torque transfer under all environmental and operating conditions. Using these signals the control
module will use strategies to protect the coupling from overheating; in extreme cases to protect the coupling from damage
the coupling will disengage if the temperature of the hydraulic fluid exceeds 105C. The coupling will return to normal
functionality when the temperature falls below 101C.
The control module has an integrated diagnostics system, which constantly monitors the active on-demand coupling system
as well as its input and output signals. If the control module detects a fault a Diagnostic Trouble Code (DTC) is stored. The
DTC is accessed using the Land Rover approved diagnostic system.
Electric Hydraulic Pump

When negotiating very low friction surfaces such as wet grass, snow or ice; initial wheel-spin can cut into the surface and
reduce grip. With a re-active on-demand coupling, almost 60 degrees of wheel rotation would occur before torque could be
transmitted through the coupling.
On Generation 3 couplings, to counteract this Land Rover developed a unique high-pressure pre-charge facility which
energizes the hydraulic circuit as soon as the engine is started. Essentially an electrically operated hydraulic pump was
designed to maintain a potential of 500 Nm (369 lb ft) of torque pressure within the coupling. (This pre-charge torque
capacity has been increased to 1500Nm (1106 lb ft) for the Generation 4 coupling.)
Vehicles fitted with Terrain Response also add further benefits by varying the level of pre-charge to deliver optimum traction
over a range of different terrain surfaces. The level of pre-charge is varied depending on the particular terrain response
mode, for example:
Terrain response in 'Special Programs Off' mode as common with vehicles without terrain response, the coupling is
programmed to transmit 500 Nm 369 lb ft of torque on Generation 3 couplings and 1500 Nm (1106 lb ft) of torque on
Generation 4 couplings to the rear axle when the vehicle moves from rest in a straight line. This strategy minimizes
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traction loss from a standing-start regardless of the terrain. When the vehicle accelerates the pressure in the coupling
is decreased to improve fuel economy.
The ability to sense the steering angle allows the coupling to be programmed to provide no torque transfer through
the coupling. This prevents the coupling locking when the vehicle is maneuvring at low speeds and acute steering
angles.
In 'Grass / Gravel / Snow' mode the coupling is programmed to maintain its pre-charge state until much higher speeds
are obtained. The same applies even if the vehicle is traveling at low speeds and acute steering angles, as traction
takes precedence over coupling lock-up on low-friction surfaces.
For additional information, refer to: Ride and Handling Optimization (204-06 Ride and Handling Optimization, Description and
Operation).
Mechanical Hydraulic Pump - Generation 3 Couplings - Vehicles up to 2009MY

The driveshaft is attached to the coupling's front clutch plate assembly (input), with the rear clutch plate assembly connected
to the differential pinion (output). A swash-plate with 6 hydraulic rollers is also attached to the differential pinion. When there
is no speed difference between the coupling's input and output, the rollers do not function.
However, when the front and rear axles start to rotate at different speeds, the swash-plate rotates relative to the rollers
which generates the hydraulic pressure. This pressure is used to force the opposing clutch plates together, increasing the
transmission of torque to the rear axle. As the difference in axle speed increases the hydraulic pressure pushes the clutch
plates further together to increase the torque to the rear axle.
A control valve/axial solenoid controls the amount of pressure applied to the clutch plates, and hence the amount of torque
transmitted to the rear wheels. Close manufacturing tolerances and exceptionally low component wear ensure torque control
remains accurate throughout the vehicle's life.
Mechanical Hydraulic Pump - Generation 4 Couplings - Vehicles from 2009MY

The Generation 4 coupling does not use the swash plate to mechanically raise hydraulic pressure; instead, a new hydraulic
pump is used to generate hydraulic pressure and force the clutch plates together. The removal of the swash plate allows a
larger overall clutch plate surface area, which in turn reduces the hydraulic pressure requirement. The pressure required to
achieve 1500Nm (1106 lb ft) has been reduced from 100 Bar for Generation 3 couplings to 40 Bar for Generation 4 couplings.
The positioning of the Generation 4 coupling's input and output remains the same as the Generation 3 coupling, as described
above.
By-pass Valve
On very low friction surfaces, driveline drag torque can occur, for example:
reverse torque from engine braking, or
forced movement of the driveshaft by the front wheels.
This can influence rear wheel speed, making it impossible to determine the true friction capability of the rear wheels, by
distorting the wheel speed signal. To prevent this, the active on-demand coupling is designed to open immediately in
response to a stability control event. This is achieved by a by-pass valve instantly reducing system pressure to nominal.
To balance the 4 bar base pressure (see below for details), the Generation 3 coupling uses a large Belleville spring to force
the clutch plates clear of each other to prevent torque transmission through the coupling. Even at 0C, torque transmission is
reduced from 300 Nm to Zero within 10 ms. The Generation 4 coupling however, does not require a Bellville spring to
separate the plates as the coupling does not have a significant base pressure pushing the plates together.
Accumulator
The further the clutch plates have to move in order to contact each other, the longer it takes to displace the hydraulic fluid
necessary to build pressure and transmit torque. To counter this, the Generation 3 coupling incorporates an accumulator. This
retains a nominal 4 bar pressure within the hydraulic circuit. Although this is not enough pressure to cause significant torque
transmission through the coupling, it forces the plates very close together so that very little fluid displacement is required to
achieve full engagement and maximum torque transfer. Full torque transmission can be achieved in 150 ms.
On Generation 4 couplings, the 150ms activation time is achieved through the use of a Bellville spring that acts to push the
plates together (without causing significant torque transmission through the coupling). As the pump is not continuously used
to create this base pressure (as it was with Generation 3 coupling), improvements in fuel economy have been achieved.
Wet Clutch Pack

The clutch pack is made up of 7 pairs of plates; the inner discs are produced from hardened steel with the outer discs
manufactured from steel with a sintered face. The clutch plates operate in transmission fluid.
Torque transmission across the clutch pack is limited to 1500 Nm (1106 lb ft). This ensures the lower gears retain an element
of front-wheel-drive for traction stability. Within the higher gears the coupling is theoretically capable of transmitting all the
drive to the rear axle; although conditions would have to be extreme for this to occur.
PRINCIPLES OF OPERATION
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Generation 3 Couplings - up to 2009MY

An internal electronically-controlled pump provides hydraulic pre-charge pressure within the coupling. The pre-charge
pressure supplies the required operating pressure to the clutch plates to eliminate initial wheel-spin as the vehicle accelerates
from standstill.
In conjunction with the pre-charge pressure a mechanical hydraulic pump operates within the clutch plates to supply the
coupling's main hydraulic operating pressure. The mechanical pump is functioned by the 'input' and 'output' of the coupling:
input - driveshaft connection from the front axle,
output - differential connection to the rear axle.
Any speed difference between the front and rear axles will start the operation of the mechanical hydraulic pump. The amount
of hydraulic pressure applied to the clutch pack by the pump determines the gap between the clutch plates. For example, the
greater the hydraulic pressure, the smaller the gap between the plates and subsequently the greater the torque transmitted
through the coupling from the front axle to the rear axle.
This main hydraulic pressure is designed to transmit the torque for traction demands of off-road driving, and to provide
lock-up as required.
Generation 4 Couplings - from 2009MY

The Generation 4 coupling still uses an electrically-controlled pump to provide hydraulic pre-charge to eliminate wheel-spin
from standstill; however, the same pump is also used to provide the coupling's main hydraulic operating pressure.
The principles of transmitting torque through the clutch plates remains the same, as described above for the Generation 3
coupling.
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Rear Drive Axle/Differential - Rear Drive Axle and Differential

Diagnosis and Testing
For additional information.
REFER to: Driveline System (205-00 Driveline System - General Information, Diagnosis and Testing).
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Rear Drive Axle/Differential - Differential Draining and Filling

General Procedures
1.
WARNING: Make sure to support the vehicle with axle stands.

CAUTION: Make sure the vehicle is on a flat level surface.
Raise and support the vehicle.
2. No provision is made to fully drain the rear differential.

During repair procedures, fluid will be lost. A container
should be positioned to collect any spillage.
3. Make sure the vehicle is level. Remove the rear differential filler plug
and discard the sealing washer.
4. Fill the rear differential, until a thin thread of fluid runs from the filler
hole.
Refer to: Specifications (205-02 Rear Drive Axle/Differential,
Specifications).
5. Using a new washer, install the drain plug.

Torque: 35 Nm
6. Lower the vehicle.
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Rear Drive Axle/Differential - Active On-Demand Coupling Filling

General Procedures
NOTE: If installing a new active on-demand coupling, fill with 650 ml of fluid. It is not possible to completely drain the active
on-demand coupling fluid during service. The procedure below MUST be followed for both filling and topping up.
1.
CAUTION: Make sure the vehicle is on a flat level surface.

2. No provision is made to fully drain the active on-demand coupling.

During repair procedures, fluid will be lost. A container should be
positioned to collect any spillage.
3.
CAUTION: This is a filler plug only and must not be

used as a fluid level indicator.
Make sure the vehicle is level. Remove the filler plug and
discard the sealing washer.
4. Fill the active on-demand coupling, until a thin thread of fluid runs
from the filler hole.
Specifications).
5. Install the active on-demand fluid filler plug.
6. Turn the ignition on for 5 minutes.
7. Turn the ignition off and remove the remote handset.
8. Fill the active on-demand coupling, until a thin thread of fluid runs
from the filler hole.
9.
CAUTION: This is a filler plug only and must not be used as a

fluid level indicator.
Using a syringe, remove exactly 70 ml of fluid.
10.
CAUTION: Replace the washer.

Install and tighten the filler plug.
Torque: 35 Nm
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Rear Drive Axle/Differential - Active On-Demand Coupling

Removal and Installation
Removal
1.

Raise the vehicle on a lift.
2. Remove the exhaust system.

Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L
Diesel, Removal and Installation).
3.
WARNING: Do not lever the driveshaft joints to

release from the power transfer unit or the rear
differential flanges.
CAUTIONS:
Mark the components to aid installation.
Make sure that the driveshaft is supported with
suitable retaining straps.
Discard the bolts.
4.
5.
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6.
Position a container to collect the oil spillage.
Discard the O-ring seal.
Installation
1. Lubricate and install a new O-ring seal.
Specifications).
2.
CAUTION: Make sure that the area around the component is

clean and free of foreign material.
Install the active on-demand coupling.
Torque: 24 Nm
3. Connect the electrical connector.
CAUTION: Make sure that new bolts are installed.
4.
NOTE: Make sure that the component is installed to the

position noted on removal.
Install the driveshaft to the active on-demand coupling.
Torque: 40 Nm
5. Install the driveshaft rear support bracket.

Torque: 35 Nm
Check and
top-up the
active on-demand coupling fluid level.
6. Install
the exhaust
system.
7.
Refer to:
to: Active
On-Demand
Coupling
Filling (205-02
Refer
Exhaust
System (309-00B
Exhaust
System -Rear
TD4 Drive
2.2L
Axle/Differential,
General
Procedures).
Diesel,
Removal and
Installation).
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Rear Drive Axle/Differential - Active On-Demand Coupling Module

Removal
NOTE: If installing a new active on-demand coupling module the sensor and throttle valve must also be installed.
1.

Raise the vehicle on a lift.
2. Disconnect the electrical connectors.
3.
CAUTION: Make sure that the area around the

component is clean and free of foreign material.
Position a container to collect the fluid spillage.
Remove and discard the gasket.
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4.
Using a suitable tool, remove the throttle valve.
5.
Using a suitable tool, remove the active on
demand coupling sensor.
Installation
1. Install the new gasket.
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2. Install the cupped washer to the sensor with the convex

side against the sensor.
3. CAUTIONS:
The throttle valve and sensor must be installed to
the active on-demand coupling module before the
assembly is installed to the active on-demand coupling.
Failure to follow this instruction may result in damage to
the vehicle.
Make sure the component is aligned as shown.
Install the sensor and washer assembly.
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4. Install the new throttle valve.
5. NOTE: Lubricate the O-ring seal.

Install the active on-demand coupling module.
Torque: 6 Nm
6. Connect the electrical connectors.
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Rear Drive Axle/Differential - Active On-Demand Coupling Oil Pump

Removal
1.

Raise the vehicle on the lift.
2. Remove the drive pinion flange.

Refer to: Drive Pinion Flange (205-02 Rear Drive Axle/Differential,
Removal and Installation).
3.
4. CAUTIONS:
Be prepared to collect escaping oil.
Make sure that the area around the component is
Discard the O-ring seals.
Installation
1.
CAUTION: Only use the specified material to lubricate the seals.

Lubricate the O-ring seals.
Specifications).
2. Install the new O-ring seals.
3.
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Install the oil pump.

Torque: 6 Nm
4. Connect the electrical connector.
5. Install the drive flange.

6. Check and top-up the active on-demand coupling fluid level.

Refer to: Active On-Demand Coupling Filling (205-02 Rear Drive
Axle/Differential, General Procedures).
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Rear Drive Axle/Differential - Active On-Demand Coupling Drive Pinion

Seal
Special Tool(s)
100-012
Slide Hammer
205-862-1
Installer, Active On-demand Pinion Seal
308-529
Remover, Seals
Removal
1.

Raise the vehicle on the lift.
2. Remove the differential drive flange.

3. Carefully remove and discard the pinion oil seal.

Special Tool(s): 308-529, 100-012
Installation
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1.
CAUTION: Only use the specified material to lubricate the seals.

Lubricate the oil seal.
Specifications).
2.
Using the special tool, install a new oil seal.
Special Tool(s): 205-862-1
Tap in the seal until the head of the drift is
against the active on-demand coupling housing.
3. Install the differential drive flange.

4. Install the exhaust system.

Refer to: Exhaust System (309-00B Exhaust System - TD4 2.2L
Diesel, Removal and Installation).
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Rear Drive Axle/Differential - Differential Case

Removal
NOTE: Removal steps in this procedure may contain installation details.
1.

2. Remove the LH rear wheel and tire.

Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and
Installation).
3. With assistance, remove the rear muffler.

Refer to: Exhaust System (309-00A Exhaust System - I6 3.2L Petrol,
4.

CAUTIONS:
Make sure that the driveshaft is supported with
suitable retaining straps.
Discard the bolts.
5.
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6.
7. Remove the LH rear halfshaft.

Refer to: Rear Halfshaft LH (205-05 Rear Drive Halfshafts, Removal
and Installation).
8. Using a transmission jack, support the differential case.
9.
CAUTION: Mark the components to aid installation.

Discard the bolts.
10.

Discard the bolts.
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11. Carefully release the RH inboard halfshaft joint from the

differential and tie aside.
12.
13. Carefully lower and remove the differential case.
14. NOTE: Do not disassemble further if the component is

removed for access only.
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15.
Installation
1.

Install a new O-ring seal to the active on-demand coupling.
2. CAUTIONS:
Make sure that the area around the component is clean and free
of foreign material.
Make sure that new bolts are installed.
Align the active on-demand coupling to the differential and tighten the
bolts.
Torque: 24 Nm
3. Install the rear differential support bracket.

Torque: 35 Nm
4. Using a transmission jack, carefully raise the assembly.
5. Connect the differential breather lines.
6. Secure the RH inner halfshaft joint to the differential.
7. CAUTIONS:
Make sure that the installation marks are aligned.

Install the rear differential front bush retaining bolts.
Torque: 175 Nm
8. CAUTIONS:
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Install the rear differential rear bush retaining bolts.
Torque: 110 Nm
9. Install the LH halfshaft.

and Installation).
10. Connect the Active On-demand Coupling module electrical connector.

Torque: 35 Nm
12.

Connect the driveshaft to the rear flange.
Torque: 40 Nm
13. Install the rear muffler.

14. Install the LH rear wheel and tire.

Installation).
16. Fill the differential case with fluid.

Refer to: Differential Draining and Filling (205-02 Rear Drive
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Rear Drive Axle/Differential - Differential Support Insulator

Removal
1.


3.

Support the rear differential using a transmission jack.
4.

Discard the bolts.
5.
Installation
1. Install the rear differential insulator to the rear differential.
Torque: 35 Nm
2. CAUTIONS:
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Install the rear differential front bush retaining bolts.
Torque: 175 Nm

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Rear Drive Axle/Differential - Differential Front Bushing

Special Tool(s)
205-860-01
Remover, Differential Bushing
205-860-02
205-860-03
Installer, Differential Bushing
205-860-04
205-860-09
205-860-10
Spacer, Differential Bushing
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LR-121
Hydraulic Cylinder 10t
Removal
1.

2. Remove both rear wheels and tires.

Installation).
3. Remove the rear differential.

Refer to: Differential Case (205-02 Rear Drive Axle/Differential,
4. CAUTIONS:
Note the fitted position of the component prior to

removal.
Using the special tools, remove the bushing.
Special Tool(s): 205-860-01, 205-860-02, 205-860-10,
LR-121
Installation
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1. Using the special tool, compress the bushing.

Special Tool(s): 205-860-09, 205-860-04, LR-121
2.
CAUTION: Make sure the correct special tool is

used to install the bushings to the correct depth.
NOTE: Make sure that these components are installed to
the noted removal position.
Using the special tool, install the bushing.
Special Tool(s): 205-860-10, 205-860-01, 205-860-04,
205-860-03, LR-121
3. Install the rear differential.

4. Install the rear wheels and tires.

Installation).
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Rear Drive Axle/Differential - Differential Rear Bushing

Special Tool(s)
205-860-09
205-861-01
205-861-02
Remover/Installer, Differential Bushing
205-861-03
205-861-04
205-861-05
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LR-121
Hydraulic Cylinder 10t
Removal
1.

2. Remove both rear wheels and tires.

Installation).

4. Take note of the fitted position of the rear bushings. The

RH bushing slot is positioned vertically and the LH
bushing slot is positioned horizontally.
5.
CAUTION: Note the fitted position of the

component prior to removal.
Using the special tool, remove the bushing.
Special Tool(s): 205-861-01, 205-861-02, LR-121
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Installation
1.
CAUTION: Only use the specified special tool.

Using the special tool, compress the bushing.
Special Tool(s): 205-860-09, 205-861-05, LR-121
2.
CAUTION: Make sure the correct special tool is

used to install the bushings to the correct depth.
NOTE: Make sure that these components are installed to
the noted removal position.
Using the special tool, install the bushing, making sure
the slot on the RH bushing is positioned vertically and
the slot on the LH bushing is positioned horizontally.
Special Tool(s): LR-121, 205-861-04, 205-861-03,
205-861-05

4. Install the rear wheels and tires.

Installation).
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Rear Drive Axle/Differential - Drive Pinion Flange

Special Tool(s)
205-053
Retainer, Drive Flange
Removal
1.


3.

Discard the bolts.
4.
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CAUTION: Make sure that the driveshaft is

supported with suitable retaining straps.
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5.
Position a container to collect the oil spillage.
Using the special tool, remove the drive flange.
Special Tool(s): 205-053
Discard the nut.
Installation
1.
WARNING: Make sure that a new nut is installed.

Using the special tool, install the drive flange.
Torque: 130 Nm
2.
NOTE: Make sure that these components are installed

to the noted removal position.
Install the driveshaft to the active on-demand coupling.
Torque: 40 Nm

Torque: 35 Nm

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Rear Drive Axle/Differential - Drive Pinion Front Bearing

Removal
1. Raise and support the vehicle.
2. Drain the differential fluid.


4. Remove the differential casing bolts.
5. Remove the differential case.
6. Remove and discard the differential case seal.
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7. Remove the crown wheel assembly.
8. Position the differential assembly in a suitable vice as

shown.
9.
CAUTION: Make sure the pinion seal recess is not

damaged as the seal is removed.
Using the special tool remove the pinion shaft oil seal.
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10.
WARNING: High torque application.

CAUTION: Do not use air tools or heat to remove
the nut (as this could contaminate the head bearing).
Failure to follow this instruction may result in damage to
the component.
NOTE: The special tool should be turned clockwise to
remove the pinion shaft nut.
Using the special tools remove the pinion shaft nut.
11.
Secure the differential casing to the special tool.
Position the support bolt to its lowest setting.
12.
CAUTION: Twisting or damage to the casing may

occur if the base plates to support the jig on the press
are not used.
Using a suitable press remove the differential pinion
shaft.
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13. Remove and discard the pinion shaft collapsible spacer.
14. Remove the tail bearing inner race.
15. Using the special tools remove the pinion shaft tail
bearing outer race.
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16.
CAUTION: It is essential that absolute cleanliness is observed

when working on the rear differential. Always cover any open orifices
using lint free non-flocking material to prevent the ingress of foreign
matter. Failure to follow this instruction may result damage to the
components.
Remove the differential from the supporting tool.
Thoroughly clean the pinion shaft paying particular attention to
the thread.
Using a suitable cleaning fluid thoroughly clean the differential
casings.
Installation
1.
CAUTION: Do not clean or lubricate the new pinion

shaft tail bearing, as it is supplied coated with a low
friction oil. Failure to follow this instruction will require
the pinion shaft tail bearing to be replaced before the
differential can be successfully assembled.
Secure the differential casing to the special tool.
Using a suitable press and the special tool install
the pinion shaft tail bearing outer race.
2. Install the new pinion shaft spacer.
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3.
Install the pinion shaft to the differential case.
Lubricate the pinion head bearing with differential
oil.
Position the support bolt to its highest setting.
4.
CAUTION: Do not clean or lubricate the new pinion

shaft tail bearing, as it is supplied coated with a low
friction oil. Failure to follow this instruction will require
the pinion shaft tail bearing to be replaced before the
differential can be successfully assembled.
Using a suitable press and the special tool install the
pinion shaft tail bearing inner race.
5.
Position the differential assembly in a suitable
vice as shown.
Remove the differential from the supporting tool.
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6.
WARNING: High torque application.

CAUTIONS:
The special tool should be turned counter clockwise
to install the pinion shaft nut.
Do not use air tools to install the nut. Failure to
follow this instruction may result in damage to the
component.
NOTE: 250 Nm (184 lb.ft) is the minimum torque
requirement to begin collapsing the pinion shaft spacer.
Using the special tools install the new pinion nut.
Tighten to 250 Nm (184 ib. ft).
7. CAUTIONS:
Make sure the specified torque to rotate the pinion
shaft is not exceeded. If excess preload is applied to the
joint the pinion shaft should be removed and a new
collapsible spacer, pinion shaft tail bearing, pinion shaft
tail bearing cup and pinion nut must be installed.
The special tool should be rotated at 60 rpm (1x
revolution per second) to produce a consistent reading.
The pinion shaft should be rotated through two full

revolutions by hand before the torque measurement is
performed.
Using the special tool, check the torque required
to rotate the pinion shaft. The specified torque is
1.1 Nm +/- 0.2 Nm
If the specified torque to rotate the pinion shaft is
not reached, using the special tools, tighten the
pinion flange nut in one degree increments and
check the rotational torque after each until the
specified torque of 1.1 Nm +/-0.2 Nm is
achieved.
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8.
CAUTION: Do not lubricate the pinion oil seal.

Using a suitable press, the special tool and adapter
install the pinion bearing oil seal.
9. Install the crown wheel assembly.
10. CAUTIONS:
Make sure the mating faces are clean, failure to
follow this instruction may result in damage to the
differential.
Make sure the new seal is not twisted when fitting,
failure to follow this instruction may result in damage to
the differential.
Install the differential case seal.
Apply a thin amount of clean differential oil to the
new differential casing seal.
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11.
Install the differential casing bolts.
Tighten the 7 bolts to 29 Nm.

13. Fill the differential case with fluid.

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Rear Drive Axle/Differential - Drive Pinion Seal

Special Tool(s)
100-012
Slide Hammer
205-865
Installer, Differential Pinion Seal
303-538
Remover/Installer, Crankshaft Oil Seal
308-615
Remover, Seals
Removal
1.

2. Remove the active on-demand coupling.

Refer to: Active On-Demand Coupling (205-02 Rear Drive
Axle/Differential, Removal and Installation).
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3. CAUTIONS:
Take extra care not to damage the edges of the

component.
Take extra care not to damage the mating faces.
Using the special tool, punch a hole in the oil seals outer
edge.
4. CAUTIONS:
Be prepared to collect escaping oil.
Using the special tools and a self tapping screw, remove
the oil seal.
Special Tool(s): 308-615, 100-012
Installation
1. CAUTIONS:
Take extra care not to damage the seal.
Make sure that the area around the component is
Using the special tool, install the new drive pinion seal.
2. Install the active on-demand coupling.

Refer to: Active On-Demand Coupling (205-02 Rear Drive
Axle/Differential, Removal and Installation).
3. Check and top-up the differential case.

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Rear Drive Axle/Differential - Rear Halfshaft Seal

Special Tool(s)
205-863
Installer, Halfshaft Seal
Removal
1.

2. Remove the wheel and tire.

Installation).
3. Remove the halfshaft.

and Installation).
4. CAUTIONS:
Take extra care not to damage the edges of the

component.
Installation
1. CAUTIONS:
Make sure that the seal is correctly located.
Take extra care not to damage the seal.
Using the special tool, install a new rear halfshaft oil
seal.
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2. Install the halfshaft.

and Installation).
3. Install the wheel and tire.

Installation).
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205-02 Rear Drive Axle Differential

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205-02 Rear Drive Axle Differential

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What is the differential type and ratio?

What is the differential type and ratio?

What are the advantages of the generation 4 active on-demand coupling?

What are the advantages of the generation 4 active on-demand coupling?

http://topix.landrover.jlrext.com/topix/service/procedure/146634/OD...

Rear Drive Axle/Differential Lubrication

Capacity (liters/pints/US quarts)

Rear Drive Axle/Differential - Rear Drive Axle and Differential

Active on-demand coupling

Active on-demand coupling module

Vehicles from 2009MY

ACTIVE ON-DEMAND COUPLING

Check valves - exhaust side

Active on-demand coupling module

Control valve / axial solenoid

Oil pressure and temperature sensor

Electric hydraulic pump

Check valve - intake side

Combined check and by-pass valve

Ring shaped annular piston

Inner connection hub with splines for outer hub.

Inner and outer wet clutch plates

The active on-demand coupling provides the following functions:

Control Module - Generation 3 and 4 Couplings

Electric Hydraulic Pump

Mechanical Hydraulic Pump - Generation 3 Couplings - Vehicles up to 2009MY

Mechanical Hydraulic Pump - Generation 4 Couplings - Vehicles from 2009MY

Wet Clutch Pack

Generation 3 Couplings - up to 2009MY

Generation 4 Couplings - from 2009MY

Rear Drive Axle/Differential - Rear Drive Axle and Differential

Rear Drive Axle/Differential - Differential Draining and Filling

WARNING: Make sure to support the vehicle with axle stands.

2. No provision is made to fully drain the rear differential.

5. Using a new washer, install the drain plug.

6. Lower the vehicle.

Rear Drive Axle/Differential - Active On-Demand Coupling Filling

CAUTION: Make sure the vehicle is on a flat level surface.

2. No provision is made to fully drain the active on-demand coupling.

CAUTION: This is a filler plug only and must not be

5. Install the active on-demand fluid filler plug.

6. Turn the ignition on for 5 minutes.

7. Turn the ignition off and remove the remote handset.

CAUTION: This is a filler plug only and must not be used as a

CAUTION: Replace the washer.

Rear Drive Axle/Differential - Active On-Demand Coupling

WARNING: Make sure to support the vehicle with axle stands.

2. Remove the exhaust system.

WARNING: Do not lever the driveshaft joints to

CAUTION: Make sure that the area around the component is

3. Connect the electrical connector.

CAUTION: Make sure that new bolts are installed.

NOTE: Make sure that the component is installed to the

5. Install the driveshaft rear support bracket.

Rear Drive Axle/Differential - Active On-Demand Coupling Module

WARNING: Make sure to support the vehicle with axle stands.

2. Disconnect the electrical connectors.

CAUTION: Make sure that the area around the

2. Install the cupped washer to the sensor with the convex