LEMON Manuals: Even more car manuals for everyone
Home >> Land Rover >> 2002 >> Range Rover >> Repair and Diagnosis >> External Pages >> Different car >> Section 32 (Differentials) >> Removal & Installation >> Front Differential Assembly >> Installation

Front Differential Assembly: Installation

WARNING: This page is about a different car, the 2005 Land Rover Range Rover, 2004 Land Rover Range Rover, and 2003 Land Rover Range Rover. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean differential mating faces. Install NEW "O" ring to differential housing and lubricate with petroleum jelly. With assistance, carefully install differential. Install bolts, but do not tighten at this stage. Align differential. See DIFFERENTIAL ASSEMBLY ALIGNMENT - FRONT  .
  2. Connect breather hose to differential. Clean subframe and body mating faces. With assistance, install subframe assembly. Using NEW bolts, tighten 6 bolts securing subframe-to-body to specification, then tighten 2 most rearward bolts a further 90 degrees. See Figure . See TORQUE SPECIFICATIONS  .
  3. Tighten bolts securing subframe-to-front cross member to specification. See TORQUE SPECIFICATIONS  . Install roll bar heat shields to body and tighten 2 bolts and speed nuts.
  4. Lower engine onto engine mountings. See Figure . Tighten nuts securing engine brackets to mountings to specification. See TORQUE SPECIFICATIONS  .
  5. Connect connector to PAS rack pinion sensor. Connect height sensor connectors. See Figure . Correctly position height sensor harness and secure with cable ties.
  6. Clean PAS pump and pipe union mating faces. Install NEW "O" ring to high pressure pipe, align pipe to PAS pump, and tighten union to specification. See TORQUE SPECIFICATIONS  .
  7. Ensure pinion timing marks are aligned and connect column to PAS rack. Install and tighten steering column lower clamp Torx bolt to specification. See TORQUE SPECIFICATIONS  .
  8. Install differential oil seal and right axle shaft. See AXLE SHAFT SEALS - FRONT  .
  9. Install right drive shaft seal. Install front drive shaft. See FRONT DRIVE SHAFT in DRIVE AXLES article. Fill differential to correct level with oil. See OIL DRAIN & REFILL PROCEDURE  under LUBRICATION.
  10. Install viscous fan to coolant pump fan assembly. Using wrenches LRT-12-214 and LRT-12-215, tighten viscous coupling lock nut. Viscous coupling lock nut thread is left handed. Install air intake plenum. Connect battery ground cable.
  11. Clean PAS fluid reservoir around filler cap and fluid level indicators. Check power steering fluid. If aerated, wait until fluid is free from bubbles then fill reservoir to UPPER level mark with recommended fluid. Install reservoir filler cap.
    12. NOTE: Ensure fluid is always present in reservoir during bleeding.
  12. Start engine and allow to idle for 10 seconds. Stop engine. Fill PAS fluid reservoir. Start engine and turn steering fully to left and right locks.
    13. CAUTION: DO NOT hold steering at full lock for longer than 10 seconds.
  13. Stop engine. Fill PAS fluid reservoir. Start and run engine at idle for 2 minutes, turn steering fully to right and left locks. Check, and if necessary, adjust steering wheel.
scientia non olet · About LEMON Manuals