300Tdi Defender
FRONT AXLE AND FINAL DRIVE
1
REPAIR
REV: 09/97
FRONT AXLE ASSEMBLY
Service repair no - 54.10.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
axle when lowering or repositioning axle.
1. Support chassis front.
2. Remove road wheels.
3. Support axle weight with hydraulic jack.
4. Remove radius arms to chassis frame nuts.
5. Disconnect steering damper from track rod.
Using a extractor remove track rod links from
swivel pin arms.
6. Remove four nuts and bolts securing radius
arms to axle bracket.
7. Remove radius arms.
8. Remove bolts securing brake hose brackets .
Refit bolts to prevent oil leakage.
9. Remove bolts from brake calipers and tie to one
side.
10. Remove nuts and washers securing shock
absorbers to axle.
11. Disconnect drag link from swivel pin housing
arm.
12. Remove two nuts and bolts securing panhard
rod to axle bracket. Lift rod clear of axle.
13. Mark for reassembly drive shaft flanges.
Remove four nuts and bolts, tie propeller shaft to
one side.
14. Release axle ventilation pipe banjo and lower
axle assembly. Remove road springs.
15. Disconnect anti-roll bar link
See FRONT
SUSPENSION, Repair, Anti-roll bar ball .
16. Remove axle assembly.
Refit
17. Position axle under vehicle, supporting left side
of axle, and fit anti-roll bar links
See FRONT
SUSPENSION, Repair, Anti-roll bar links .
18. Fit propeller shaft. Tighten bolts to
47 Nm (35
lbf/ft).
19. Fit panhard rod to axle bracket. Tighten bolts to
88 Nm (65 lbf/ft).
20. Fit drag link to swivel pin arm. Tighten fixings to
40 Nm (30 lbf/ft).
21. Fit shock absorbers to axle.
22. Fit brake calipers. Tighten bolts to
82 Nm (60
lbf/ft).
23. Tighten upper swivel pin bolts to
78 Nm (58
lbf/ft).
24. Fit radius arms to axle brackets. Tighten bolts to
197 Nm (145 lbf/ft).
25. Fit steering damper to track rod.
26. Fit radius arms to chassis side member. Tighten
fixings to
197 Nm (145 lbf/ft).
27. Tighten track rod end to
40 Nm (30 lbf/ft) and fit
new split pin.
28. Remove chassis supports, fit road wheels and
tighten to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -
100 Nm (80 lbf/ft)
Heavy duty wheels -
170 Nm (125 lbf/ft)
