300Tdi Defender
FRONT AXLE AND FINAL DRIVE
5
OVERHAUL
38. Place retaining plate, joint washer and oil seal
over axle flange ready for assembly.
39. Fit swivel bearing housing to axle flange with 7
bolts. Tighten to
73 Nm (54 lbf/ft).
40. Grease and fit upper and lower swivel pin taper
roller bearings.
41. Position swivel pin housing over swivel bearing
housing.
42. Coat joint washer both sides with sealing
compound and position on lower swivel pin.
43. Loosely fit brake shield bracket plus lower swivel
pin with lug outboard to swivel pin housing.
44. Loosely fit top swivel pin plus existing shims and
brake hose bracket to swivel pin housing.
45. Apply Loctite 270 or equivalent to lower swivel
pin bolts.
78 Nm (58 lbf/ft), bend over lock tabs.
46. Tighten top swivel pin bolts to
78 Nm (58 lbf/ft).
Check and adjust preload on bearings
NOTE: Swivel housing oil seal and axle
should not be fitted.
47. Attach a spring balance to ball joint bore and pull
balance to determine effort required to turn
swivel pin housing.
Resistance, once initial inertia has been
overcome, should be 1.16 to 1.46 kg. Adjust by
removing or adding shims to top swivel pin.
48. When setting is correct remove top swivel bolts,
apply Loctite 270 or equivalent. Refit bolts and
tighten to
78 Nm (58 lbf/ft), and bend over lock
tabs.
49. Apply recommended grease between lips of
swivel oil seal.
50. Fit oil seal, joint washer and retaining plate with
7 bolts and spring washers. Tighten to
11 Nm (8
lbf/ft).
51. Fit tie rod and drag link and secure with new
cotter pins. Tighten fixing to
40 Nm (30 lbf/ft).
52. Fit brake disc shield.
53. Loosely fit lock stop bolt and nut.
54. Apply a recommended grease between lips of
swivel housing oil seal.
55. Secure oil seal with retaining plate and securing
bolts. Tighten to
11 Nm (8 lbf/ft).
56. Fit track-rod and drag link and secure with new
cotter pins.
57. Loosely fit lock stop bolt for later adjustment.
58. Fit brake disc shield.
Fit driveshaft and stub axle
59. Insert axle shaft, and when differential splines
are engaged, push assembly in fully.
CAUTION: Take care not to damage axle
shaft oil seals.
60. Place a new joint washer in position on swivelpin
housing to stub axle mating face. Coat threads
of stub axle bolts with Loctite 270.
61. Fit stub axle with flat at 12 O’clock position.
CAUTION: Ensure that constant velocity
joint bearing journal is butted against
thrust ring on stub axle before stub axle is
secured.
62. Place mud shield in position and secure stub
axle to swivel pin housing with 6 bolts and
tighten evenly to
65 Nm (48 lbf/ft).
63. Fit brake jump hoses to brake jump hose
bracket.
64. Fit complete front hub assembly
See Repair,
Front hub assembly .
65. Check swivel pin housing oil drain plug is fitted.
66. Fill swivel assembly to correct level, with new oil
See SECTION 10, Maintenance, Under
vehicle maintenance .
NOTE: On later vehicles fill swivel pin
housing with 0.33 Litres of Molytex EP 00
grease.
67. Set steering lock stop bolts
See STEERING,
Adjustment, Steering lock stops .
