Land Rover Defender: Drive Pinion Seal

REMOVAL AND INSTALLATION

SPECIAL TOOL(S)

100-012

Slide Hammer

100-012-01

Slide Hammer Adapter

204-266

Adapter for 204-265

204-269A

Flange remover forcing screw

205-053

Retainer, Differential Pinion Flange

307-520

Installer, Output Shaft Seal

JLR-205-1014

Remover/Installer, Differential Pinion Flange

JLR-205-1015A

Installer, Halfshaft

JLR-205-1031

Remover, Differential Pinion Seal

JLR-205-998

Installer, Rear Differential Seal

REMOVAL

WARNING: Be prepared to collect escaping oil.

NOTE:

• This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
• This procedure contains illustrations showing certain components removed to provide extra clarity.

1. Raise and support the vehicle on a suitable 2 post lift.

2. Drain the rear differential oil.

3. Remove the rear driveshaft.

4.

Measure the distance between the top surface of the pinion nut and the top surface of the pinion shaft.

5.

Mark the pinion nut in relation to the pinion shaft.

6.

• Install the special tool to prevent the pinion from rotating when removing the pinion nut.

  Special Tool(s): 205-053

7.

Remove the pinion nut.

8. Remove the special tool.

Special Tool(s): 205-053

9.

Mark the position of the pinion flange in relation to the pinion shaft.

10.

• Assemble the special tools as illustrated.

  Special Tool(s): JLR-205-1014, 204-266

11.

Install the special tools to the pinion flange.

12.

• Use the special tools to remove the pinion flange.

  Special Tool(s): 204-269A

13.

• Assemble the special tools as illustrated.

  Special Tool(s): 100-012, 100-012-01, JLR-205-1031

14.

• Install the special tool and tighten the bolt until the jaws are fully engaged with the pinion seal.
• Use the special tools to remove the pinion seal.

15.

CAUTION: Make sure the differential pinion bearings are not contaminated.

• Clean and inspect the differential case to differential pinion seal mating face.
• Clean and inspect the pinion shaft splines and threads.
• Clean and inspect the pinion flange splines.

INSTALLATION

1.

• Make sure that the new pinion seal is correctly installed to the special tool.
• Use the special tools to install the new pinion seal.

  Special Tool(s): JLR-205-998, 307-520

2.

• Apply thread locking fluid to splines.
• Install the pinion flange. Make sure the marks are correctly aligned.

3.

• Install the special tool to the pinion shaft.

  Special Tool(s): JLR-205-1015A

4.

• Assemble the special tools as illustrated.

  Special Tool(s): 204-266, JLR-205-1014

5.

Install the special tools to the pinion flange.

6.

• Use the special tools to install the pinion flange.
• Remove the special tools.

7.

Install the special tool.

Special Tool(s): 205-053

8.

CAUTION:

• Make sure that the line scribed on the pinion nut aligns with the line on the pinion shaft.
• Never under tighten the pinion nut.
• Never over tighten the pinion nut by more than 5 degrees past the scribed lines.

• Apply thread locking fluid to threads.
• Install and tighten the pinion nut.
• Check the measurement from the top surface of the pinion nut and the top surface of the pinion shaft is the same as in the removal step.
• Make sure the pinion flange has no end float and is free to rotate.

9. Remove the special tool.

10. Refill the rear differential.

11. Install the rear driveshaft.

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