Disassemble Front Differential

DISASSEMBLE FRONT DIFFERENTIAL

1. Remove and discard the left-hand driveshaft oil seal from the differential housing.





2. Remove the 12 differential casing bolts. (Figure 11)





3. Using the recess, release the front differential upper casing. (Figure 12)

CAUTION:
Ensure the bearing cup and shim are retained in the differential casing.





4. Remove the differential upper casing. (Figure 13)





5. Remove the crown wheel assembly. (Figure 14)

CAUTION:
Do not use solvents or cleaning agents of any type to clean the differential (as this could contaminate the head bearing), clean with a dry cloth only.

6. Clean the differential mating faces.

CAUTION:
Ensure that the bearing cup and shim are retained in the differential casing and all case-to-tool bolts are used. Failure to follow these directions may cause damage to the special tool.





7. Install the differential casing and pinion assembly to special tool 205-890. (Figure 15)





8. Position the special tool in a suitable vice. (Figure 16)

CAUTION:
Do not use air tools or heat to remove the nut (as this could contaminate the head bearing). Failure to follow this instruction may result in damage to the component. Do not tighten the bolt used to locate special tool 205-891 in special tool 205-890.





9. Using special tool 205-891, remove and discard the pinion flange nut. (Figure 17)

CAUTION:
Twisting or damage to the differential housing / special tool may occur if base plates are not used to support the special tool in the press or the four jig fixings are not used.

10. Remove the special tool from the vice and position the assembly in a suitable hydraulic press.

CAUTION:
Suitable hand and eye protection must be worn when removing the pinion flange.

CAUTION:
During the removal process, the pinion may be expelled from the differential housing with considerable force. Do not use hands in an attempt to 'catch' the pinion during the removal process.

CAUTION:
To avoid damaging the pinion, prevent the pinion from contacting differential housing /workbench during the removal process.

CAUTION:
Do not exceed 15 tons of pressure when removing the pinion flange. If difficulty is encountered during this operation, contact the Land Rover Technical HelpLine for further assistance.





11. Using special tool 205-893, remove the pinion flange from the pinion shaft assembly. (Figure 18)

CAUTION:
Ensure that the pinion seal recess is not damaged as the seal is removed.





12. Remove and discard the pinion seal. (Figure 19)





13. Remove and retain the pinion shaft tail bearing for return. (Figure 20)

14. Remove and retain the collapsible spacer for return.





15. Wipe shaft with a clean cloth. (Figure 21)

CAUTION:
Ensure special tool 205-895 is installed between the two bearing cups.





16. Using special tools 205-895 and 100-012 remove and retain the pinion shaft tail bearing cup for return. (Figure 22)