Differentials Land Rover Range Rover L322

AXLE RATIO & IDENTIFICATION

AXLE RATIO SPECIFICATIONS

GENERAL

Front and rear differentials convert the "angle of drive" through 90 degrees and distribute drive, via the axle shafts, to the front and rear wheels. (Scheme 1) The front differential is mounted on the left side of the engine sump. The rear differential is mounted on the rear subframe.

Scheme 1

FRONT DIFFERENTIAL

The front differential is mounted on the left side of the vehicle sump. The sump has a cast tube through it, which allows for the installation of the right axle shaft and separates the engine oil from the differential oil. The differential unit is secured to the engine sump with 4 bolts. The bolts pass through lugs in the differential housing and are secured into threaded holes in the sump. An "O" ring seal is installed to the housing and locates in the sump to provide a seal between the housing and the sump.

The housing comprises 2 halves with machined mating faces. (Scheme 2) When assembled, the iron housing halves are sealed with a thin film of Loctite 574 sealant and secured together with 12 bolts. The left housing is the carrier for all the rotating parts and the right housing is a cover to close the unit and a support for the right carrier bearing. A breather tube is installed to the housings. This allows a plastic tube to be installed and routed to a high point in the engine compartment, preventing the ingress of water when the vehicle is wading through water.

The left housing is installed with a drain plug and a filler/level plug. The level plug allows the unit to be filled with oil until it leaks from the filler hole, ensuring the correct quantity of oil is added.

The differential is a conventional design using a hypoid gear layout. This employs a hypoid bevel pinion gear and crown wheel, with the pinion offset below the center line of the crown wheel. This design allows for a larger pinion gear to be used which has the advantages of increased gear strength and reduced operating noise. (Scheme 3)

The differential comprises a pinion shaft and hypoid bevel gear, a crown wheel drive gear with an integral cage which houses 2 planet gears. There are 2 sun wheels located in the cage and pass the rotational drive to the drive shafts.

The pinion shaft is mounted on 2 opposed taper roller bearings with a collapsible spacer located between them. The spacer is used to hold the bearings in alignment and also collapses under the pressure applied to the pinion nut. This allows the nut to be tightened to a predetermined torque, which collapses the spacer, setting the correct bearing preload.

The pinion shaft has an externally splined outer end which accepts and locates the input flange, which is retained by the pinion nut. The opposite end of the output flange has an internal spline which provides positive location for the front drive shaft. The flange has an external "O" ring seal which seals against the front drive shaft shroud preventing the ingress of dirt and moisture into the splines. An oil seal is pressed into the left housing and seals the input flange to the differential unit. The pinion shaft has a hypoid bevel gear at its inner end which mates with the crown wheel drive gear.

The crown wheel drive gear is located on the carrier and secured with 10 bolts. The carrier is mounted on taper roller bearings located in each housing half. The bearings are press fitted into the housing and a spacer is located on the outside face to apply preload to the bearing.

The carrier is installed with a shaft onto which the 2 planet gears are mounted. The shaft is secured in the carrier with a roll pin. The sun wheels are located in pockets within the carrier and mesh with the planet gears. Curved plates are located between the carrier and the sun wheels and hold the sun wheels in mesh with the planet gears. Each sun wheel has a machined, splined, bore to accept the drive shaft. A groove is machined in the bore to locate the snap ring fitted to the drive shaft, providing positive drive shaft location.

Scheme 2

Scheme 3

REAR DIFFERENTIAL

The rear differential is located centrally in the rear subframe. The front of the rear differential is attached to the subframe via rubber bushings and bolts. The rear of the differential is mounted to the subframe via a single, offset rubber bushing and a bolt. (Scheme 4)

The housing comprises 2 parts. The pinion housing is made from cast iron and provides locations for all the internal components. The pinion housing is sealed at the rear by an aluminum casting which is secured to the pinion housing with 8 bolts and spring washers. A gasket between the 2 housings seals the unit. The rear cover has cast fins which assist heat dissipation. A breather tube is installed to the rear cover. This allows a plastic tube to be installed and routed to a high point under the vehicle body, preventing the ingress of water when the vehicle is wading through water.

The rear cover contains an oil level plug which allows for oil filling and level checking, with the differential installed in the vehicle. The level plug allows the unit to be filled with oil until it leaks from the filler hole, ensuring the correct quantity of oil is added.

The differential is a conventional design using a hypoid gear layout, similar to the front differential. The differential comprises a pinion shaft and spiral bevel pinion gear and a crown wheel drive gear with an integral cage which houses 2 planet gears. There are 2 sun wheels located in the cage which pass the rotational drive to the axle shafts.

The pinion shaft is mounted on 2 opposed taper roller bearings, with a collapsible spacer located between them. (Scheme 4) The spacer is used to hold the bearings in alignment and also collapses under the pressure applied to the pinion flanged nut. This allows the flanged nut to be tightened to a predetermined torque, which collapses the spacer, setting the correct bearing preload.

The pinion shaft has an externally splined outer end which accepts and locates the input flange, which is retained by the pinion nut. The output flange has 6 threaded holes and mates with the rear drive shaft. The 6 bolts secure the rear drive shaft to the input flange. An oil seal is pressed into the pinion housing and seals the input flange to the pinion housing. The pinion shaft has a spiral bevel gear at its inner end which mates with the crown wheel drive gear.

The crown wheel drive gear is located on the carrier and secured with 10 bolts. The carrier is mounted on taper roller bearings located in machined bores on each side of the pinion housing. The bearings are retained in the housing by a circlip, the thickness of which is selected to apply the correct bearing preload.

The carrier has a through hole which provides location for the shaft. The shaft provides the mounting for the planet gears in the carrier cage. The shaft is installed with a snap ring at one end which locates in a machined groove in the carrier, locking the shaft in position.

The sun wheels are located in pockets in the carrier cage and mesh with the planet gears. Spacers are installed between the sun wheels and the carrier and set the correct mesh contact between the planet gears and the sun wheels. Each sun wheel has a machined bore with internal splines and machined groove near the splined end. The groove provides positive location for a snap ring installed to the end of each output flange.

Each output flange has a splined shaft located in each sun wheel. A snap ring is installed to the splined shaft in a groove in the sun wheel bore to locate the output flange. Oil seals are pressed into each side of the pinion housing and seal the output flange to the housing. Each output flange has 6 threaded holes which provide for the attachment of the rear axle shafts.

The rear cover is located on the rear of the pinion housing and is sealed to the housing with a gasket and secured with 8 bolts.

Scheme 4

OPERATION

The operating principles of the front and rear differentials are the same. Rotational input from the drive shaft is passed via the input flange to the pinion shaft and pinion gear. The angles of the pinion gear to the crown wheel drive gear moves the rotational direction through 90 degrees.

The transferred rotational motion is now passed to the crown wheel drive gear, which in turn rotates the carrier. The shaft, which is secured to the carrier also rotates at the same speed as the carrier. The planet gears, which are mounted on the shaft, also rotate with the carrier. In turn, the planet gears transfer their rotational motion to the left and right hand sun wheels, rotating the axle shafts.

When the vehicle is moving in a forward direction, the torque applied through the differential to each sun wheel is equal. In this condition both axle shafts rotate at the same speed. The planet gears do not rotate and effectively lock the sun wheels to the carrier.

If the vehicle is turning, the outer wheel will be forced to rotate faster than the inner wheel by having a greater distance to travel. The differential senses the torque difference between the sun wheels. The planet gears rotate on their axes to allow the outer wheel to rotate faster than the inner one.

CAPACITY

DIFFERENTIAL FLUID CAPACITY

FLUID TYPE

Manufacturer recommends using only Castrol SAF-X0 for front and rear differentials.

1. Raise and support vehicle. Position container to catch spillage. Clean area surrounding drain and filler/level plugs. (Scheme 5) Remove drain plug and collect fluid.
2. Apply sealant STC 50552 to drain plug, install and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications). Remove filler/level plug.
3. Measure required quantity of recommended lubricant into a clean container. See «CAPACITY»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__capacity) and «FLUID TYPE»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__fluid-type). If a thread of lubricant runs/drips from the filler plug after refilling, then differential has been overfilled.
4. Drain lubricant and refill using correct quantities. Apply sealant STC 50552 to filler plug, install and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications).

Scheme 5

1. Raise and support vehicle. Position container to catch spillage. Clean area surrounding drain and filler/level plugs. (Scheme 6) Remove drain plug, discard sealing washer and allow oil to drain.
2. Clean drain plug, install NEW sealing washer and tighten plug to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications). Remove filler/level plug and discard sealing washer.
3. Fill axle using recommended lubricant until a thread of oil runs from level/filler plug. See «FLUID TYPE»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__fluid-type). Allow time for lubricant to find common level.
4. Install NEW sealing washer and tighten filler/level plug to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications). Lower vehicle.

Scheme 6

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL INFORMATION.

DISCONNECTING & CONNECTING BATTERY

1. Before disconnecting battery negative cable it is imperative that ignition key be removed from ignition switch. After removing ignition key WAIT at least 2 minutes before disconnecting battery negative cable. Failure to do so could result in navigation computer hardware damage and/or incorrect fuel gauge reading. Before disconnecting battery, disable alarm system and turn off all electrical equipment.
2. After reconnecting battery negative cable, the steering wheel must be turned to full left and right lock (with engine running). This allows DSC system to relearn steering wheel position. Failure to do so will result in a variety of instrument warning lights being illuminated.

Removal

1. Raise and support vehicle. Disconnect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__disconnecting-connecting-battery). Remove air intake plenum. Remove 3 screws and remove plenum intake cover. Lift flap and remove filter.
2. Release clips and remove towing eye finisher. Remove 6 screws securing air dam to underpanel. Remove 2 screws securing air dam support brackets to bumper. Carefully ease air dam aside for access and remove 4 screws.
3. Release 3 coolant hoses from clips on fan cowl. Remove screw securing fan cowl to radiator. Disconnect harness connector and release cooling fan connector from mounting. Using wrenches LRT-12-214 and LRT-12-215, loosen viscous coupling lock nut and remove fan assembly from coolant pump. Viscous coupling lock nut thread is left handed.
4. Remove scrivets securing fan cowl. Place container under Power Assist Steering (PAS) pump, release pipe union and allow fluid to drain. (Scheme 7) Plug connections. Remove and discard "O" ring from PAS pipe. Remove 2 nuts securing engine brackets to mountings. (Scheme 8) Connect chain to lifting bracket and take weight off engine.
5. Drain oil from differential. See «OIL DRAIN & REFILL PROCEDURE»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials) under LUBRICATION. Remove front drive shaft. See FRONT DRIVE SHAFT in «DRIVE AXLES»(/land-rover/range-rover/l322-2002-2005/remont/driveshaft-universal-joints/#driveshafts-universal-joints) article.
6. Remove right axle shaft and differential axle seal. See «AXLE SHAFT SEALS - FRONT»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials).
7. Remove Torx bolt from steering column lower clamp. (Scheme 9) Rotate steering wheel to straight ahead position, align pinion timing marks and remove ignition key.
8. Disconnect column from pinion. Note installed position for reinstallation, then remove cable ties securing height sensor harness to sub frame and sensors. (Scheme 10) Disconnect height sensor connectors.
9. Disconnect connector from PAS rack pinion sensor. (Scheme 9) Remove 2 speed nuts securing each roll bar heat shield to body and 2 bolts securing each heat shield to subframe. (Scheme 11) Remove heat shields. Use transmission jack to support subframe.
10. Remove 6 bolts securing subframe. (Scheme 12) Remove and discard 2 bolts securing subframe to crossmember. With assistance, lower and remove subframe assembly.
11. Remove differential breather hose. Remove 4 differential securing bolts and with assistance, remove differential. Discard "O" ring. (Scheme 18)

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Installation

1. Clean differential mating faces. Install NEW "O" ring to differential housing and lubricate with petroleum jelly. With assistance, carefully install differential. Install bolts, but do not tighten at this stage. Align differential. See «DIFFERENTIAL ASSEMBLY ALIGNMENT - FRONT»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__front-differential-assembly-alignment).
2. Connect breather hose to differential. Clean subframe and body mating faces. With assistance, install subframe assembly. Using NEW bolts, tighten 6 bolts securing subframe-to-body to specification, then tighten 2 most rearward bolts a further 90 degrees. (Scheme 12) See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications).
3. Tighten bolts securing subframe-to-front cross member to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications). Install roll bar heat shields to body and tighten 2 bolts and speed nuts.
4. Lower engine onto engine mountings. (Scheme 8) Tighten nuts securing engine brackets to mountings to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications).
5. Connect connector to PAS rack pinion sensor. Connect height sensor connectors. (Scheme 10) Correctly position height sensor harness and secure with cable ties.
6. Clean PAS pump and pipe union mating faces. Install NEW "O" ring to high pressure pipe, align pipe to PAS pump, and tighten union to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications).
7. Ensure pinion timing marks are aligned and connect column to PAS rack. Install and tighten steering column lower clamp Torx bolt to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications).
8. Install differential oil seal and right axle shaft. See «AXLE SHAFT SEALS - FRONT»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials).
9. Install right drive shaft seal. Install front drive shaft. See FRONT DRIVE SHAFT in «DRIVE AXLES»(/land-rover/range-rover/l322-2002-2005/remont/driveshaft-universal-joints/#driveshafts-universal-joints) article. Fill differential to correct level with oil. See «OIL DRAIN & REFILL PROCEDURE»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials) under LUBRICATION.
10. Install viscous fan to coolant pump fan assembly. Using wrenches LRT-12-214 and LRT-12-215, tighten viscous coupling lock nut. Viscous coupling lock nut thread is left handed. Install air intake plenum. Connect battery ground cable.
11. Clean PAS fluid reservoir around filler cap and fluid level indicators. Check power steering fluid. If aerated, wait until fluid is free from bubbles then fill reservoir to UPPER level mark with recommended fluid. Install reservoir filler cap.
12. Start engine and allow to idle for 10 seconds. Stop engine. Fill PAS fluid reservoir. Start engine and turn steering fully to left and right locks.
13. Stop engine. Fill PAS fluid reservoir. Start and run engine at idle for 2 minutes, turn steering fully to right and left locks. Check, and if necessary, adjust steering wheel.

FRONT DIFFERENTIAL ASSEMBLY ALIGNMENT

Note. When a NEW front differential is installed, the following alignment procedure MUST be carried out before fully tightening the differential bolts and installation of the front drive shaft. In addition, this procedure is to be used in conjunction with any procedure where the front differential assembly has been disturbed.

Checking Alignment

1. Remove and discard the "O" ring from the differential drive tube. (Scheme 13) Thoroughly clean differential drive tube splines and drive shaft splines, ensuring ALL grease is removed. Install drive shaft to the differential drive tube.
2. Slide drive shaft forwards and install centering flange to drive shaft. (Scheme 14) Temporarily secure centering flange with a suitable nut and bolt.
3. Rotate centering flange to allow Alignment Tool LRT-54-032 to be placed in position. (Scheme 15) Remove one slider from alignment tool and set aside. Position alignment tool into the bushing opening in the transfer gearbox front output flange. (Scheme 16)
4. Using a 2-mm Allen wrench, loosen slider screw so slider moves freely along ruler. Slide drive shaft rearwards until centering flange nipple is nearly in contact with alignment tool surface. (Scheme 16) Position alignment tool vertically with slider below centering flange nipple.
5. Gently pull drive shaft down to its lowest position. Tighten slider screw to identify extent of movement. Record measurement on alignment tool, at inside edge of slider. (Scheme 16)
6. Loosen the slider screw so that slider moves freely along ruler. Position alignment tool vertically with slider above centering flange nipple. Gently push drive shaft up to its highest position and move slider down to top of centering flange nipple.
7. Tighten slider screw using Allen wrench. Record measurement on alignment tool, at inside edge of slider. (Scheme 17)
8. If recorded measured distances above and below locating bushing are equal within 0.039" (1.0 mm), differential is correctly aligned to transfer box front output flange. Install front drive shaft. See FRONT DRIVE SHAFT in «DRIVE AXLES»(/land-rover/range-rover/l322-2002-2005/remont/driveshaft-universal-joints/#driveshafts-universal-joints) article.
9. If the measured distances are not equal within 0.039" (1.0 mm), adjust differential alignment. See «ADJUSTING DIFFERENTIAL»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__adjusting-differential).

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Adjusting Differential

Note. Rotating differential counterclockwise will raise drive tube. This will decrease excess distance below locating bushing. (Scheme 16) This procedure may need to be repeated several times to achieve desired result.

Note. The calculated average measurement is the TARGET position (maximum up and down) for the drive shaft in relation to the locating bushing in the transfer gearbox front output flange.

1. Slide drive shaft forwards, release centering flange securing nut and bolt, rotate centering flange and remove alignment tool. (Scheme 15) Calculate average of up and down recorded measurements to obtain the TARGET measurement.
2. Release slider screw on Alignment Tool LRT-54-032 and move inside edge of slider to the calculated TARGET position. Fully tighten slider screw using the Allen wrench.
3. Position alignment tool into transfer gearbox front output flange locating bushing. (Scheme 15) Rotate centering flange into position and secure with a suitable nut and bolt. Slide drive shaft rearwards until it contacts the face of the ruler.
4. If measured distance was larger below than above locating bushing center line, position alignment tool vertically with slider above centering flange nipple. If measured distance was larger above than below locating bushing center line, position alignment tool vertically with slider below centering flange nipple.
5. Perform differential alignment as follows: Release 4 differential attachment bolts sufficiently to secure the differential, but still allow slight rotation on its axis. (Scheme 18) Gently push drive shaft up or pull drive shaft down until centering flange nipple touches inside edge of slider. With assistance, hold drive shaft in this position and snugly tighten one differential bolt to secure the differential. Verify that the measurement above and below centering flange nipple is equal and the same as the TARGET measurement. Repeat adjustments up and down as required to achieve equal alignment measurements.
6. When measurement is equal above and below locating bushing within 0.039" (1.0 mm) of TARGET position, tighten all front differential mounting bolts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications). Verify that measurement above and below centering flange nipple remain equal after mounting bolts have been tightened.

1. Raise and support vehicle. Remove front road wheels. Remove right brake disc. Release ABS sensor lead from clip. Release sensor lead from shock absorber, remove Allen screw and release ABS sensor from hub. Remove nuts securing roll bar links and release links from roll bar.
2. Remove nut securing height sensor link to lower arm and release link.
3. Loosen bolt securing lower arm to subframe one quarter turn. Remove nut securing lower arm ball joint to hub. Using Ball Joint Separator LRT-54-027, release lower arm ball joint and disconnect lower arm from hub. Loosen bolt securing tie rod to subframe one quarter turn. Remove nut securing tie rod to ball joint.
4. Using Ball Joint Separator LRT-54-027, release tie rod from ball joint. Remove and discard nut securing track rod ball joint to steering arm. Install M14 nut to ball pin, flush with end of pin. Using Ball Joint Separator LRT-57-036, separate ball pin from steering arm. Remove M14 nut and release ball pin from steering arm.
5. Position container to collect oil spillage. Install Axle Shaft Remover LRT-54-026 to axle shaft inboard joint. Using levers, release axle shaft from differential. Remove 2 nuts and bolts securing hub to shock absorber. With assistance, remove hub and axle shaft assembly. Remove and discard shaft retaining clip. Carefully remove and discard oil seal.

1. Clean differential axle shaft oil seal register. Using Oil Seal Installer LRT-54-028, install NEW oil seal. Clean end of axle shaft. Lubricate lip of oil seal with differential oil.
2. Install NEW circlip to axle shaft. Lightly lubricate splines and oil seal running surface. With assistance, position hub and axle shaft assembly. Carefully install axle shaft through seal, remove seal protector and push axle shaft fully home to engage retaining clip.
3. Align hub to shock absorber and tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) . Clean ball joint tapers and taper seats.
4. Connect Ball joint to steering arm, install NEW nut and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) . Connect Tie rod to ball joint, install nut and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) .
5. Connect height sensor link to lower arm, install nut and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) . Connect lower arm ball joint to hub, install nut and tighten to specification.
6. Connect roll bar links, install nuts and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) .
7. Clean ABS sensor, smear sensor with an anti-seize grease and install sensor to hub. Install Allen screw securing ABS sensor and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) . Secure sensor lead to shock absorber.
8. Install front brake disc. Install road wheel and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) . Lower vehicle.
9. Tighten Bolt securing lower arm to subframe to specification, plus a further 90 degrees. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) . Tighten Bolt securing tie rod to subframe to specification, plus a further 90 degrees.
10. Check front wheel alignment and adjust as necessary. Ensure differential oil level is correct. See «OIL DRAIN & REFILL PROCEDURE»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials) under LUBRICATION.

REAR DIFFERENTIAL ASSEMBLY

Note. Rear differential may also be referred to as the final drive.

1. Raise and support vehicle. Disconnect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__disconnecting-connecting-battery). Release precatalyst harness leads from clips, remove connectors from retaining clips and disconnect.
2. Release post catalyst HO2S harnesses from clips, remove connectors from clips and disconnect. Remove and discard 4 nuts securing front pipe flanges to exhaust manifolds, release front pipe from flanges and move aside. Remove and discard 4 nuts securing intermediate silencer mountings to body.
3. Remove 8 nuts securing center heat shield and remove shield. (Scheme 19) Remove 8 hexagonal headed screws securing fuel tank heat shield and remove shield. (Scheme 20)
4. Reference mark drive shaft and differential to aid reassembly. (Scheme 21) Remove 6 nuts securing drive shaft to differential flange. Remove 2 nuts securing drive shaft support bearing and lower drive shaft. Release flange from differential. Temporarily support bearing and secure with nuts. Remove road wheels.
5. Disconnect breather hose from differential. Drain oil from differential. See «OIL DRAIN & REFILL PROCEDURE»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials) under LUBRICATION.
6. Reference mark axle shaft and differential flanges to aid reassembly. Remove 6 bolts securing axle shaft to differential drive flange and collect 3 bolt plates. (Scheme 22) Discard bolts. Position jack to support lower arm. Remove nut and bolt securing lower arm to hub.
7. Remove support jack. Release lower arm from hub and disconnect drive shaft from differential. Repeat procedure for other side. Support weight of differential assembly on a jack. Remove and discard 2 bolts and one nut and bolt securing differential to subframe. (Scheme 23) Remove differential assembly.

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

1. Position jack and raise differential into position. Install NEW bolts securing differential to subframe and tighten front 2 bolts to specification and NEW rear nut and bolt to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) .
2. Clean end of axle shaft and location in differential. Locate axle shaft to differential. Clean lower arm and hub mating faces. Align hub to lower arm, install and lightly tighten nut and bolt. Clean axle shaft bolt plates, position plates and install NEW bolts. Tighten axle shaft to differential drive flange bolts to specification plus a further 60 degrees. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) .
3. Repeat procedure for other side. Connect breather hose to differential. Install road wheel and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) . Lower vehicle.
4. Tighten bolts securing lower arms to hubs to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) . Clean differential and drive shaft flange mating faces. Remove nuts securing support bearing, connect drive shaft to differential flange and locate support bearing.
5. Install nuts securing support bearing but do not tighten at this stage. Install nuts securing drive shaft to differential flange and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) . Tighten nuts securing drive shaft support bearing to specification.
6. Install fuel tank heat shield and secure with screws. Install center heat shield and secure with nuts. Fill differential to correct level with oil. See «OIL DRAIN & REFILL PROCEDURE»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials) under LUBRICATION.
7. Install rubbers to exhaust mounting brackets and main assembly. With assistance, install exhaust system to vehicle. Align flanges to manifolds, install and lightly tighten bolts. Install one pair of rear silencer brackets to body and lightly tighten bolts.
8. Align remaining exhaust mounting brackets to body, install nuts and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) . Check exhaust for correct alignment. Align exhaust flange and tighten NEW nuts evenly to specification. Connect battery negative cable. Start and run engine to check for exhaust leaks.

1. Raise and support vehicle. Remove road wheel.
2. Remove 6 bolts securing axle shaft to differential drive flange and collect 3 bolt plates. (Scheme 22) Discard bolts.
3. Position jack to support lower arm. Remove nut and bolt securing lower arm to hub. Lower support jack. Release axle shaft from differential. Position container to collect oil spillage.
4. Using a soft metal drift, release and remove drive flange. (Scheme 24) Remove circlip from shaft and discard. Carefully remove and discard oil seal, take care not to damage oil seal recess.

Scheme 24

1. To install, clean oil seal recess. Install oil seal using Seal Installer LRT-51-021. (Scheme 25) Clean drive flange and oil seal running surface.
2. Install NEW circlip to shaft. (Scheme 24) Lightly lubricate splines and oil seal running surface. Install drive flange.
3. Clean lower arm and hub mating faces. Locate axle shaft to differential. Align hub to lower arm, install and lightly tighten nut and bolt.
4. Clean and position bolt plates. Install NEW bolts securing axle shaft to differential drive flange and tighten to specification plus a further 60 degrees. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications).
5. Install road wheel and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications). Lower vehicle. Tighten bolt securing lower arm to hub to specification. Ensure differential oil level is correct. See «OIL DRAIN & REFILL PROCEDURE»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials) under LUBRICATION.

Scheme 25

Removal & Installation

1. Remove rear differential assembly. See «DIFFERENTIAL ASSEMBLY - REAR»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__rear-differential-assembly) . Remove 8 bolts securing differential rear cover. Remove rear cover. Remove and discard gasket.
2. To install, clean rear cover and mating face on differential. Position gasket and cover. Install bolts and working in a diagonal sequence, progressively tighten differential rear cover bolts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications) . Install differential assembly. See «DIFFERENTIAL ASSEMBLY - REAR»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__rear-differential-assembly) .

Removal (Front Bushings)

1. Raise and support vehicle. Disconnect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__disconnecting-connecting-battery).
2. Reference mark drive shaft and differential to aid reassembly. (Scheme 21) Remove 6 nuts securing drive shaft to differential flange. Remove 2 nuts securing drive shaft support bearing and lower drive shaft. Release flange from differential. Temporarily support bearing and secure with nuts.
3. Release clips securing differential breather pipe to body. Support rear differential on jack. Remove and discard 2 front bolts and one rear nut and bolt securing differential to subframe. (Scheme 23) Carefully lower jack, allow differential and axle shafts to rest on lower suspension arms.
4. Rotate differential through 90 degrees for access. Install LRT-51-023/3 to LRT-51-023/5. (Scheme 26) Install and finger-tighten nut. Install LRT-51-023/1 to subframe. Ensure slots face away from bushing.
5. Install LRT-51-023/2 to LRT-51-023/1, install nut to drawbar and finger-tighten. Note fitted position of bushing and paint mark on subframe. (Scheme 26) Remove bushing from rear subframe. Dismantle bushing remover tool and recover bushing.

Scheme 26

1. Clean bushing housing and mating faces. Apply rubber lubricant to NEW bushing and bore. Install NEW bushing to LRT-51-023/1. Install LRT-51-023/4 through LRT-51-023/1 to retain bushing. (Scheme 27)
2. Locate LRT-51-023-/5 through bushing housing in subframe and screw to LRT-51-023/4. Install LRT-51-023/2 to LRT-51-023/5. Install and finger-tighten nut. Install bushing to rear subframe. Remove and dismantle tool.
3. Position jack and raise differential into position. Install NEW front bolts, and NEW rear bolt and nut securing differential to subframe. Tighten bolts and NEW rear nut and bolt to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications).
4. Remove support jack. Install and secure differential breather pipe to clips on body. Install rear drive shaft. Connect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__disconnecting-connecting-battery).

Scheme 27

Removal (Rear Bushing)

1. Raise and support vehicle. Disconnect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__disconnecting-connecting-battery).
2. Reference mark drive shaft and differential to aid reassembly. (Scheme 21) Remove 6 nuts securing drive shaft to differential flange. Remove 2 nuts securing drive shaft support bearing and lower drive shaft. Release flange from differential. Temporarily support bearing and secure with nuts.
3. Release clips securing differential breather pipe to body. Support rear differential on jack. Remove and discard 2 front bolts and one rear nut and bolt securing differential to subframe. (Scheme 23) Carefully lower jack, allow differential and axle shafts to rest on lower suspension arms.
4. Carefully lower jack, allow differential and drive shafts to rest on lower suspension arms. Rotate differential through approximately 135 degrees for access and tie aside.
5. Note installed position of bushing and paint mark subframe. Position LRT-51-022/2 to subframe. Install LRT-51-022/5 through bushing and screw to LRT-51-022/2. (Scheme 28)
6. Position LRT-51-022/1 to LRT-51-022/5, install nut to drawbar and finger-tighten. Remove bushing from rear subframe. Dismantle tool and recover bushing.

Scheme 28

1. Clean bushing housing and mating faces. Apply rubber lubricant to NEW bushing and bore. Position LRT-51-022/3 to subframe. (Scheme 29) Install LRT-51-022/5 to LRT-51-022/3.
2. Position NEW bushing to LRT-51-022/5. Install LRT-51-022/4 to LRT-51-022/5 and finger-tighten nut. Install bushing to rear subframe. Remove and dismantle tool.
3. Position jack and raise differential into position. Install NEW front bolts, and NEW rear bolt and nut securing differential to subframe and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications).
4. Remove support jack. Install and secure differential breather pipe to clips on body. Install rear drive shaft. Connect battery negative cable. See «DISCONNECTING & CONNECTING BATTERY»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__disconnecting-connecting-battery).

Scheme 29

1. Raise and support vehicle. Remove 8 nuts securing center heat shield and remove shield. (Scheme 19) Remove 8 hexagonal headed screws securing fuel tank heat shield and remove shield. (Scheme 20)
2. Reference mark drive shaft and differential to aid reassembly. (Scheme 21) Remove 6 nuts securing drive shaft to differential flange. Remove 2 nuts securing drive shaft support bearing and lower drive shaft. Release flange from differential and temporarily support bearing and secure with nuts.
3. Remove and discard locking plate. (Scheme 30) Reference mark pinion nut and pinion shaft to aid reassembly. Using Spanner Wrench LRT-51-003 restrain pinion flange and remove nut. (Scheme 31)
4. Position container to collect oil spillage. Using a 2-legged puller remove pinion flange. (Scheme 32) Carefully remove and discard oil seal, take care not to damage oil seal recess.

Scheme 30

Scheme 31

Scheme 32

1. Clean oil seal recess. Using Drift LRT-12-179 with Seal Installer Adapter LRT-51-019, install NEW oil seal. (Scheme 33)
2. Clean pinion flange. Install pinion flange and nut. Using Spanner Wrench LRT-51-003 restrain pinion flange. Tighten nut to align reference marks. Install NEW locking plate.
3. Clean differential and drive shaft flange mating faces. Remove nuts securing support bearing. Connect drive shaft to differential flange and locate support bearing. Install nuts securing support bearing, but DO NOT tighten at this stage.
4. Install nuts securing drive shaft to differential flange and tighten to specification. See «TORQUE SPECIFICATIONS»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials__torque-specifications). Tighten nuts securing drive shaft support bearing to specification.
5. Install fuel tank heat shield and secure with screws. Install center heat shield and secure with nuts. Ensure differential oil level is correct. See «OIL DRAIN & REFILL PROCEDURE»(/land-rover/range-rover/l322-2002-2005/remont/differentials-drive-axles/#differentials) under LUBRICATION.

Scheme 33

OVERHAUL

Note. Manufacturer does not provide overhaul procedures for front or rear differential assemblies.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• DRIVE AXLES
• TORQUE SPECIFICATIONS
• CAPACITY
• FLUID TYPE
• DISCONNECTING & CONNECTING BATTERY
• OIL DRAIN & REFILL PROCEDURE
• DIFFERENTIAL ASSEMBLY ALIGNMENT - FRONT
• ADJUSTING DIFFERENTIAL
• DIFFERENTIAL ASSEMBLY - REAR