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Differential Assembly: Reassembling

  1. Lubricate all components with recommended oil and lightly oil the differential bolt threads.
  2. Secure rear half of differential carrier in a soft jawed vice.
  3. Fit each planet gear to its respective cross shaft, fit NEW dished thrust washer to each gear. See Fig 1 .
  4. Fit cross shafts, planet gears and dished thrust washers in rear half of carrier. See Fig 1 . ENSURE that cross shafts are fitted correctly. DO NOT fit the sun gear into the rear half carrier at this stage.
  5. Fit retaining ring. See Fig 1 .
  6. Fit a 1.05 mm (0.04") thrust washer to sun gear from front half of carrier. See Fig 1 . Position gear in front half of carrier.
  7. Ensuring that assembly marks are aligned, fit both halves of carrier together. See Fig 1 .
  8. Fit the differential carrier bolts and, working in a diagonal sequence, tighten the bolts to 60 N.m (44 ft. lbs.). See Fig 1 .
  9. Insert the front output shaft into the front half of the carrier and check that the gears rotate freely. See Fig 2 .
  10. Fit output flange on to the splines of the output shaft, but DO NOT fit flange nut at this stage. See Fig 2 .
  11. Fit transmission brake drum to output flange and secure the drum using 2 nuts. See Fig 2 .
  12. Secure a length of cord around the drum and attach one end of the cord to a spring balance. See Fig 2 .
  13. Pull on the spring balance and note the load at which the brake drum starts to turn. Used gears should rotate smoothly, while NEW gears will have a notchy feel as they rotate.
  14. Compare the figure obtained with the following:
    • Used gears = 0.45 kg (1.0 lb.).
    • New gears = 1.72 kg (3.8 lbs.).
  15. If the load to turn figure is below the specified limits, proceed as follows.
  16. Remove the front output shaft and brake drum.
  17. Remove the 8 bolts securing the two halves of the differential carrier.
  18. Separate the differential carrier and remove the sun gear and thrust washer from the front half.
  19. Select a thicker thrust washer from the range available. There are 5 different thrust washers are available, rising in increments of 0.10 mm (0.004") from 1.05-1.45 mm (0.04-0.06").
  20. Repeat steps 7 to 19 as necessary until the load to turn figure is as specified.
  21. When specified load to turn is obtained, proceed as follows.
  22. Remove the front output shaft and brake drum.
  23. Remove the 8 bolts securing the two halves of the differential carrier.
  24. Separate the differential carrier and remove the sun gear and thrust washer from the front half. Retain the selected thrust washer with its sun gear.
  25. Remove retaining ring, then remove the planet gears and cross shafts.
  26. Fit a 1.05 mm (0.04") thrust washer to sun gear from rear half of carrier. Position gear in rear half of carrier. See Fig 3 .
  27. Fit planet gears, cross shafts and dished thrust washers to rear half of carrier. Ensure that cross shafts are fitted correctly. Do not fit the sun gear into the rear half carrier at this stage. See Fig 3 .
  28. Fit retaining ring. See Fig 3 .
  29. Ensuring that assembly marks are aligned, fit both halves of carrier together. See Fig 3 .
  30. Fit the differential carrier bolts and, working in a diagonal sequence, tighten the bolts to 60 N.m (44 ft. lbs.). See Fig 3 .
  31. Invert the assembly in the vice, insert the rear output shaft into the rear half of the carrier and check that the gears rotate freely. See Fig 4 .
  32. Fit output flange on to the splines of the output shaft, but do not fit flange nut at this stage.
  33. Fit transmission brake drum to output flange and secure the drum using 2 nuts. See Fig 4 .
  34. Carry out the load to turn check, using the same method as for the front half carrier. Record the shim thickness when the load to turn is correct.
  35. Fit the sun gear and selected thickness shim to the front half carrier.
  36. Ensuring that assembly marks are aligned, fit both halves of carrier together.
  37. Fit the differential carrier bolts and, working in a diagonal sequence, tighten the bolts to 60 N.m (44 ft. lbs.).
  38. With differential assembled, fit rear output shaft and brake drum, then check overall load to turn. This should be approximately the same as the combined load to turn figure of both front and rear half carriers:
    • Used gears = 0.90 kg (2.0 lbs.).
    • New gears = 3.44 kg (7.6 lbs.).
Fig 1: Exploded View Of Transfer Box Front Half Of Differential Carrier
G00368478Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 2: Checking Front Half Carrier Bearings Torque-To-Turn
G00368479Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 3: Exploded View Of Differential Carrier
G00368480Courtesy of LAND ROVER NORTH AMERICA, INC.
Fig 4: Checking Rear Half Carrier Bearings Torque-To-Turn
G00368481Courtesy of LAND ROVER NORTH AMERICA, INC.
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