Component Dismantling

Component Dismantling

High/low cross shaft housing







1. Slacken locknut and remove neutral warning lamp switch - Range Rover Classic only - if fitted.
2. Remove setscrew securing high/low selector finger to cross shaft.
3. Withdraw cross shaft from housing, recover high/low selector finger.
4. Remove and discard 'O' ring.

Front output housing







1. Remove 7 bolts securing differential lock selector side cover, remove cover.
2. Up to serial no. 288709E: Remove and discard gasket.
3. Remove 3 bolts securing differential lock selector housing, remove housing and selector as an assembly.
4. Remove and discard 'O' ring from selector housing.
5. Remove plug securing differential lock detent spring and ball.
6. Remove detent spring.
7. Remove ball using a stick magnet.

CAUTION: Suitably identify plug, detent spring and ball to their fitted positions, do not interchange with high/low selector shaft detent components.







8. Compress differential lock selector fork spring and remove retaining clip from each end of spring.







9. Withdraw differential lock selector shaft from front output housing, recover spring.
10. Remove differential lock selector fork.







11. Position propeller shaft flange holding tool LRT-51-003 to output shaft flange.
12. Remove and discard self-locking nut.







13. Remove steel and felt washers, discard felt washer.
14. Remove output shaft flange together with mud shield.

NOTE: A replacement output flange will be supplied together with new mud shield and output shaft oil seal.







15. Using a mallet, drive output shaft out of front output housing.

NOTE: If it is necessary to use a hand press to remove output shaft, position thrust button LRT-370-11/2 between shaft and press mandrel.

16. Noting its fitted position, remove dog clutch from output shaft.
17. Noting its fitted position, remove bearing spacer from output shaft.







18. Taking care not to damage front output housing, remove and discard output shaft oil seal.







19. Using suitable circlip pliers, remove and discard circlip retaining output shaft bearing.







20. Support front output housing on suitable blocks of wood.
21. Using a soft metal drift, drive output shaft bearing out of housing; discard bearing.







22. Invert front output housing.
23. Using a soft metal drift, drive differential bearing track out of housing, discard bearing track.
24. Remove selective shim.

Rear output housing







1. Position propeller shaft flange holding tool LRT-51-003 to output shaft flange.
2. Remove and discard self-locking nut.







3. Remove steel and felt washers, discard felt washer.
4. Remove output shaft flange together with circlip.

NOTE: A replacement output flange will be supplied together with new output shaft oil seal.







5. Carefully lever speedometer driven gear and housing out of rear output housing.
6. Remove and discard 'O' ring.
7. Withdraw speedometer driven gear from housing, remove and discard oil seal from housing.







8. Position rear output housing on bed of hand press.
9. Position thrust button LRT-37-11/2 between end of output shaft and press mandrel.
10. Press output shaft out of housing.







11. Recover spacer and speedometer drive gear from output shaft.







12. Using a screwdriver inserted in slot in rear output housing, lever mud shield out of housing.

CAUTION: Discard mud shield if it is damaged.







13. Taking care not to damage rear output housing, remove and discard output shaft oil seal.







14. Using suitable circlip pliers, remove and discard circlip retaining output shaft bearing.







15. Support rear output housing on suitable blocks of wood.
16. Using a soft metal drift, drive output shaft bearing out of housing; discard bearing.

Main casing







1. Support main casing on suitable blocks of wood.
2. Using a soft metal drift, drive differential rear bearing track out of main casing; discard bearing track.







3. Invert main casing.
4. Using a soft metal drift, drive mainshaft input gear bearing track out of main casing; discard bearing track.

Mainshaft input gear bearing housing







1. Secure mainshaft input gear bearing housing in a soft-jawed vice.
2. Using a soft metal drift, drive input gear bearing track out of housing; discard bearing track.
3. Remove selective shim.

Intermediate gears







1. Secure intermediate gears in a soft-jawed vice.
2. Using a soft metal drift, drive intermediate shaft bearing track out of gears; discard bearing track.
3. Remove and discard circlip.
4. Repeat above procedure for remaining bearing track.

Mainshaft input gear assembly







NOTE: Defender input gear illustrated.

1. Secure hand press LRT-99-002 in a vice.
2. Assemble collars LRT-41-003 around bearing to be removed.
3. Position mainshaft in hand press, remove and discard bearing.
4. Repeat above procedure for remaining bearing.

Differential lock selector







1. Remove and discard self-locking nut retaining selector lever.
2. Remove washer and selector lever.
3. Withdraw selector finger and shaft from housing.
4. Remove and discard 'O' ring.

Differential
1. Secure differential in a soft-jawed vice.
2. Remove staking from bearing retaining nut.







3. Remove nut using tool LRT-41-007; discard nut.







4. Secure hand press LRT-99-002 in a vice.
5. Secure collars LRT-41-001 around rear bearing.

NOTE: This bearing is adjacent to threaded end of differential shaft.

6. Position differential in hand press with thrust button, part of tool LRT-41-001 between press mandrel and differential shaft.
7. Press differential out of bearing.

CAUTION: Take care that differential does not drop out of bearing.

8. Remove differential from press, discard bearing.







9. Remove high range gear and bush taking care not to disturb high/low selector sleeve.
10. Make suitable alignment marks between high/low selector sleeve and hub.
11. Remove high/low selector sleeve.







12. Using a suitable puller and thrust button, part of tool LRT-41-001, remove high/low hub and low range gear







13. Secure hand press LRT-99-002 in a vice.
14. Assemble collars LRT-41-002 around front bearing.

NOTE: This bearing is adjacent to splined end of differential shaft.

15. Position differential in hand press with thrust button, part of tool LRT-41-001 between press mandrel and differential shaft.
16. Press differential out of bearing.

CAUTION: Take care that differential does not drop out of bearing.

17. Remove differential from press, discard bearing.







18. Secure rear half of differential carrier in a soft-jawed vice.
19. Make suitable alignment marks between front and rear halves of differential carrier.
20. Remove 8 bolts securing front half of carrier to rear, remove carrier.
21. Suitably identify front sun gear to front half of carrier, remove sun gear.
22. Remove and discard thrust washer.
23. Suitably identify each planet gear to its shaft and fitted position of each cross shaft to rear half of carrier.
24. Remove retaining ring.
25. Remove planet gears and cross shafts, remove and discard dished thrust washers.
26. Suitably identify rear sun gear to rear half of carrier, remove sun gear.
27. Remove and discard thrust washer.