Center Differential Unit: Reassembling

1. Fit selected thrust washer and bevel gear into rear differential unit. Assemble both pinion assemblies and dished washers on to their respective shafts and fit rear differential unit. Secure assemblies with retaining ring. Lubricate all components. Fit selected thrust washer and bevel gear into front upper differential unit. Align both units as previously described and secure with 8 bolts to specified torque. See TORQUE SPECIFICATIONS  .
2. Check overall torque required to turn differential. This should be approximately equal to resistance of both bevel gears added together. Locate front differential bearing onto front, upper differential shaft and press into position using larger end of tool (18G1424) as shown. Invert differential unit and secure in vice. See Fig 1 .
   NOTE: During the following sequences all parts should be lubricated as they are fitted.
3. (38) Fit low range gear, with its dog teeth away from differential assembly. Press high/low hub on to differential splines. Slide high/low selector sleeve on to high/low hub ensuring that alignment marks are opposite each other. Fit bush into high range gear so that flange is fitted on opposite side of gear to dog teeth. Slide bushed gear on to differential assembly with dog teeth down. See Fig 2 .
4. Locate rear differential bearing on to hub and press it into position using smaller end of tool (18G1424). Fit stake nut and tighten to specified torque using tool (18G1423). Check end float of high and low range gears .05-.15 mm (.002-.006"). See Fig 3 . Peen stake nut collar by carefully forming collar of nut into slot as illustrated. See Fig 4 . Clean and check high/low selector fork assembly for wear and replace if necessary.
   NOTE: If clearances vary from those specified in data, at beginning of overhaul: assembly must be rebuilt using relevant new parts.
   CAUTION: A round nose tool must be used for this operation to avoid splitting collar of nut.
5. To replace selector fork remove set screw and slide fork from shaft. Fit new selector fork with its boss towards three detent grooves. Align tapped hole in fork boss with indent in shaft nearest to detent grooves. Apply Loctite 290 to set screw threads and fit set screw and tighten to specified torque. See Fig 5 .

Fig 1: Center Differential Unit - Assembly (1 Of 5)

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Fig 2: Center Differential Unit - Assembly (2 Of 5)

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Fig 3: Center Differential Unit - Assembly (3 Of 5)

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Fig 4: Center Differential Unit - Assembly (4 Of 5)

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Fig 5: Center Differential Unit - Assembly (5 Of 5)

Courtesy of LAND ROVER NORTH AMERICA, INC.