Drivetrain - Front Differential Alignment Process
No: 54/03/03/NAS
Ref:
Issue: 1
Date: 06/06/03
Front Differential Alignment Process
AFFECTED VEHICLE RANGE:
New Range Rover (LM) All
SITUATION:
ALIGNMENT FOR DIFFERENTIAL REPLACEMENT REQUIRED
The required procedure for differential alignment during replacement is not thoroughly covered in the RAVE Workshop Manual.
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RESOLUTION:
FOLLOW DIFFERENTIAL ALIGNMENT PROCESS
For component longevity it is important that the differential and the transfer box front output flange are correctly aligned. A process has been
developed to ensure proper alignment of the transfer gearbox front output flange and the front differential.
CAUTION:
Any damage or wear to the differential drive tube splines, requires that the whole differential assembly be replaced as well as the prop shaft. The
differential assembly includes a collapsible spacer that determines the bearing preload. There is currently no acceptable procedure for renewing a
drive tube in service. If an attempt is made to change the drive tube only, rapid failure of the differential bearings will occur. Damaged or worn
splines in the drive tube will have affected the prop shaft, requiring replacement.
PARTS INFORMATION:
WARRANTY CLAIMS:
NOTE:
This SRO time is additional time that may be claimed in addition to the published SRO for Differential Replacement (54.10.01)
54.10.89/34 Time 0.20 hrs.
Check and adjust front differential alignment
FAULT CODE: A
Normal warranty policy and procedures apply.
Material allowance is included in labor operation.
REPAIR PROCEDURE
DIFFERENTIAL ALIGNMENT
CAUTION:
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 propeller shaft.
NOTE:
This alignment procedure will be incorporated into the RAVE Workshop Manual at the next edition.
1. Remove and discard the 0 ring from the differential drive tube ("A" Figure 1).
NOTE:
All grease must be removed.
2. Thoroughly clean the differential drive tube splines ("B" in Figure 1) and the propeller shaft splines.
3. Fit the propeller shaft to the differential drive tube.
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4. Slide the propeller shaft forwards and fit the centering flange ("A" in Figure 2) to the propeller shaft.
5. Secure the centering flange with a nut and bolt ("B" Figure 2).
6. Slide the propeller shaft rearwards until the centering flange nipple is near to its locating bushing in the transfer gearbox front output flange
(Figure 2).
7. Gently pull the propeller shaft down to its lowest position.
8. Measure and record the distance between the centering flange nipple and the center of the locating bushing in the transfer gearbox front output
flange (Figure 3).
9. Gently push the propeller shaft up to its highest position.
10. Measure and record the distance between the centering flange nipple and the center of the locating bushing in the transfer gearbox front output
flange (Figure 4).
11. If the measured distances are equal both above and below the locating bushing (Figures 3 & 4), the differential is correctly aligned to the
transfer box front output flange. Go to section Install Front Propeller Shaft".
12. If the measured distances are not equal, go to section Adjustment of Differential Alignment".
ADJUSTMENT OF DIFFERENTIAL ALIGNMENT
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CAUTION:
Unequal alignment measurements as depicted in Figures 5 and 6 require differential alignment to the transfer box output flange.
1. Tighten the four differential bolts (Arrowed in Figure 7) sufficiently to secure the differential but allow it to rotate slightly on its axis.
NOTE:
Rotating the differential counter-clockwise will raise the drive tube. This will decrease the distance below the locating bush (shown in Figure 6).
This procedure may need to be repeated several times to achieve the desired result.
2. Lightly push or pull the propeller shaft to rotate the differential as required to achieve equal distance above and below the centering flange
spigot and the locating bush (see Figures 3 & 4).
3. Gently tighten one of the differential bolts to hold the differential in position.
4. Measure the distance above and below the locating bushing as follows:
^ Gently pull the propeller shaft down to its lowest position.
^ Measure and record the distance between the centering flange nipple and the center of the locating bushing.
^ Gently push the propeller shaft up to its highest position.
^ Measure and record the distance between the centering flange nipple and the center of the locating bushing.
CAUTION:
A Torque wrench MUST be used when tightening the differential fixing bolts to 110 Nm (81 lbf.ft).
5. If the measurements remain unequal, loosen the snugged differential bolt and go to Step 2 to repeat the adjustment process for the desired
results.
6. When the recorded distance is equal above and below the locating bushing, tighten all differential bolts to 110 Nm (81 lbf.ft).
INSTALL THE PROPELLER SHAFT
1. Slide the propeller shaft forwards and remove the nut and bolt securing the centering flange to propeller shaft.
2. Remove the centering flange.
3. Remove the front propeller shaft.
4. Install a new 0 ring (TYX000070) to the drive tube.
CAUTION:
ONLY use grease TIA500010. Use of any other grease or lubricant will result in premature spline wear.
5. Lubricate the 0 ring running surface with grease from packet (TIA500010).
6. Evenly distribute all of the remaining grease in the packet onto the propeller shaft splines and the drive tube splines.
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7. Install the propeller shaft into the differential drive tube.
8. Inspect the centering flange dust seal and install a new seal if indicated.
9. Clean the coupling and the centering flange mating faces.
10. Position the coupling and flange with arrows on coupling pointing towards the flange mounting. (Figure 8)
11. Install bolts securing the coupling and tighten new nuts to 110 Nm (81 lbf.ft).
12. Lower the vehicle onto its wheels.
