Front differential cup (Defender 2007+)

Special tool (s)

Ball joint puller 205-754 (LRT-54-027)

Removing

1.

WARNING: It is forbidden to carry out work on a vehicle supported only by a jack. Be sure to install reliable supports under the car.

Raise and support the vehicle.

2.

NOTE: Clean the area around the fill and drain plugs of the front axle.

Drain the fluid from the front axle assembly.

• Install a container to collect liquid.
• Remove the filler plug.
• Remove the drain plug.

3. Remove the front wheels complete with tires.

4. Remove the tie rod protection. Turn out 2 bolts.



5.

CAUTION: Before disconnecting or removing components, clean the area around contact surfaces and connections. Plug all open connections to avoid contamination of the system.

Disconnect the left front wheel speed sensor. Release the wiring harness from the clamp.



6.

CAUTION: Before disconnecting or removing components, clean the area around contact surfaces and connections. Plug all open connections to avoid contamination of the system.

Disconnect the left front brake line. Pinch the brake hose to prevent fluid loss.



7. Release the left front brake hose. Loosen the nut.



8. Using the special tool, release the tie rod end.

• Remove and discard the split pin.
• Loosen the nut.
• Remove the puck.

9. Disconnect the left tie rod using the special tool.

• Remove and discard the split pin.
• Loosen the nut.
• Pick up the puck.

10.

CAUTION: Do not allow the pivot pin housing to hang on the axle shaft. Failure to follow this instruction may result in damage to the vehicle.

With assistance, remove the left pivot pin housing.

• Remove 7 bolts.
• Remove and discard the gasket.

11.

CAUTION: Before disconnecting or removing components, clean the area around contact surfaces and connections. Plug all open connections to avoid contamination of the system.

Disconnect the right front wheel speed sensor. Release the wiring harness from the clamp.



12.

CAUTION: Before disconnecting or removing components, clean the area around contact surfaces and connections. Plug all open connections to avoid contamination of the system.

Disconnect the right front brake line. Pinch the brake hose to prevent fluid loss.



13. Release the right forward brake hose. Loosen the nut.



14. Using the special tool, release the right tie rod end.

• Remove and discard the split pin.
• Loosen the nut.
• Remove the puck.

15.

CAUTION: Do not allow the pivot pin housing to hang on the axle shaft. Failure to follow this instruction may result in damage to the vehicle.

With assistance, remove the right pivot pin housing.

• Remove 7 bolts.
• Remove and discard the gasket.

16.

NOTE: Discard nuts.

Reinstall the front anti-roll bar. Remove 4 nuts and remove bolts.



17.

NOTE: Discard nuts.

Release the front drive shaft.

• Remove 4 nuts and remove bolts.
• Using a suitable clamp, secure the drive shaft.

18. Remove the front differential housing. Loosen and discard 10 nuts.

Installation

1.

NOTE: Clean the contact surfaces of the elements.

NOTE: Install new nuts.

Install the front differential housing.

• Apply a bead of the specified sealant to the contact surface of the differential housing.
• Tighten nuts (tightening torque 41 Nm).

2.

NOTE: Install new nuts.

Attach the front drive shaft. Tighten nuts and bolts (tightening torque 47 Nm).

3.

NOTE: Install new nuts.

Attach the front anti-roll bar. Tighten nuts and bolts (tightening torque 68 Nm).

4.

CAUTION: Support axle shaft when installing pivot pin housing. Failure to follow this instruction may result in damage to the vehicle.

NOTE: Clean the contact surfaces of the elements.

With assistance, install the right pivot pin housing.

• Install a new gasket.
• Apply the prescribed sealant to the bolts.
• Tighten the bolts (tightening torque 73 Nm).

5. Fix a tip of the right steering draft.

• Install the washer.
• tighten the nut (tightening torque 40 Nm).
• Install a new pin.

6. Attach the right front brake hose. tighten the nut (tightening torque 10 Nm).

7.

NOTE: Remove and discard plugs.

Connect the right front brake line.

• Tighten connection (tightening torque 15 Nm).
• Remove the hose clamp.

8.

NOTE: Remove and discard plugs.

Install the right front wheel speed sensor. Attach the wiring harness to the clamp.

9.

CAUTION: Support axle shaft when installing pivot pin housing. Failure to follow this instruction may result in damage to the vehicle.

NOTE: Clean the mating surfaces of the parts.

With assistance, install the left pivot pin housing.

• Install a new gasket.
• Apply the prescribed sealant to the bolts.
• Tighten the bolts (tightening torque 73 Nm).

10. Fix a tip of the left steering draft.

• Install the washer.
• tighten the nut (tightening torque 40 Nm).
• Install a new pin.

11. Fix a tip of longitudinal steering draft.

• Install the washer.
• tighten the nut (tightening torque 40 Nm).
• Install a new pin.

12. Attach the left front brake hose. tighten the nut (tightening torque 10 Nm).

13.

NOTE: Remove and discard plugs.

Connect the left front brake line.

• Tighten connection (tightening torque 15 Nm).
• Remove the hose clamp.

14.

NOTE: Remove and discard plugs.

Install the left front wheel speed sensor. Attach the wiring harness to the clamp.

15. Establish protection of steering draft. Tighten the bolts (tightening torque 30 Nm).

16. Fill the front axle assembly with the correct volume of the prescribed fluid.

• Screw in and tighten the drain plug (tightening torque 60 Nm).
• Screw in and tighten the fill plug (tightening torque 60 Nm).
• Place the container.

17. Remove the air from the front brakes.

For more information, refer to the chapter: Bleeding the brake system (206-00 Brake system - General information, General procedures).

18. Install the front wheels with tires. Tighten wheel nuts (tightening torque 140 Nm).