10/9/13 TOPIx - WSM-7811 - Workshop manual Freelander 2 2007-10

Published: 11-May-2011
Rear Drive Axle/Differential - Drive Pinion Front Bearing
Removal and Installation

Removal

1. Raise and support the vehicle.

2. Drain the differential fluid.

Refer to: Differential Draining and Filling (205-02 Rear Drive

Axle/Differential, General Procedures).

3. Remove the rear differential.

Refer to: Differential C ase (205-02 Rear Drive

Axle/Differential, Removal and Installation).

4. Remove the differential casing bolts.

5. Remove the differential case.

6. Remove and discard the differential case seal.

7. Remove the crown wheel assembly.

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8. Position the differential assembly in a suitable

vice as shown.

9. C AUTION: Make sure the pinion seal recess

is not damaged as the seal is removed.

Using the special tool remove the pinion shaft oil

seal.

10. WARNING: High torque application.

C AUTION: 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.

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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. C AUTION: 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.

13. Remove and discard the pinion shaft collapsible

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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. C AUTION: 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. C AUTION: 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.

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.

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4. C AUTION: 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.

C AUTIONS:

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. C AUTIONS:

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.

8. C AUTION: Do not lubricate the pinion oil

seal.

Using a suitable press, the special tool and

adapter install the pinion bearing oil seal.

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9. Install the crown wheel assembly.

10. C AUTIONS:

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.

11.
Install the differential casing bolts.
Tighten the 7 bolts to 29 Nm.

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12. Install the rear differential.

Refer to: Differential C ase (205-02 Rear Drive

Axle/Differential, Removal and Installation).

13. Fill the differential case with fluid.

Refer to: Differential Draining and Filling (205-02 Rear Drive

Axle/Differential, General Procedures).

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