Discovery 2. Manual — part 164

FRONT AXLE

REPAIRS

54-5

REPAIRS

Differential - assembly

$% 54.10.01

Remove

1. Raise front of vehicle.

WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.

2. Remove front road wheels.
3. Drain oil from differential.

+

MAINTENANCE, PROCEDURES,

Front and rear axle.

4. If same components to be refitted, reference

mark propeller shaft and mating components.

5. Remove 4 nuts and bolts securing propeller

shaft to differential. Release propeller shaft and
tie aside.

6. Remove LH and RH front brake discs.

+

BRAKES, REPAIRS, Brake disc -

front.

7. Disconnect each ABS sensor multiplug.

8. Release each harness from brake hose and

hose bracket.

FRONT AXLE

54-6

REPAIRS

9. Remove 4 bolts securing each front wheel hub

to front axle.

10. Release wheel hubs from front axle. Remove

wheel hubs and drive shafts from front axle.

11. Remove oil seal from axle casing.

12. Remove 10 bolts securing differential to axle

casing. Release and remove differential from
axle casing.

Refit

1. Clean drive shaft oil seal recess, oil seal

running surface, wheel hub and axle mating
faces.

2. Using a suitable solvent, remove all traces

sealant from differential and axle mating faces.

3. Applysealant, Part No. STC 3811 to differential

or axle mating face.

4. Apply sealant, Part No. STC 50552 to threads

of differential securing bolts.

5. Fit differential to axle, fit bolts and tighten to 55

Nm (41 lbf.ft).

6. Position propeller shaft and align reference

marks. Fit bolts and tighten to 47 Nm (35 lbf.ft).

7. Lubricate oil seal lip and running surface with

clean differential oil.

+

CAPACITIES, FLUIDS,

LUBRICANTS AND SEALANTS,
Lubrication.

8. Using LRT-54-012 and LRT-99-003, fit new

drive shaft oil seal to axle casing.

9. Apply anti-seize compound to wheel hub and

steering knuckle mating faces.

10. Ensure ABS harnesses are located in cut out in

steering knuckles.

11. Fit drive shafts in axle casing and align wheel

hubs with steering knuckles. Fit wheel hub bolts
and tighten to 100 Nm (74 lbf.ft).

12. Connect each ABS sensor multiplug and

secure harness to harness bracket and brake
hose.

FRONT AXLE

REPAIRS

54-7

13. Fit front brake discs.

+

BRAKES, REPAIRS, Brake disc -

front.

14. Fit front road wheels and tighten nuts to 140

Nm (103 lbf.ft).

15. Remove stand(s) and lower vehicle.
16. Fill differential with oil.

+

MAINTENANCE, PROCEDURES,

Front and rear axle.

Seal - differential pinion

$% 54.10.20

Remove

1. Raise front of vehicle.

WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.

2. Reference mark front propeller shaft for

reassembly.

3. Remove 4 nuts and bolts securing propeller

shaft to differential. Release propeller shaft and
tie aside.

4. Using LRT-51-003 to restrain pinion flange,

remove bolt and washer securing pinion flange.
Remove pinion flange.

5. Position container to catch oil spillage.

FRONT AXLE

54-8

REPAIRS

6. Using a suitable lever, remove pinion oil seal.

Take care to avoid damage to oil seal
recess.

Refit

1. Clean pinion oil seal recess and pinion flange.
2. Lubricate pinion oil seal lip with clean

differential oil.

+

CAPACITIES, FLUIDS,

LUBRICANTS AND SEALANTS,
Lubrication.

3. Using LRT-51-010 , fit pinion oil seal.

4. Fit pinion flange and securing bolt and washer.

Using LRT- 51-003, restrain pinion flange and
tighten pinion flange bolt to 100 Nm (74 lbf.ft).

5. Position propeller shaft and align reference

marks. Fit nuts and bolts and tighten to 47 Nm
(35 lbf.ft).

6. Remove stand(s) and lower vehicle.
7. Check differential oil level.

+

MAINTENANCE, PROCEDURES,

Front and rear axle.