Range Rover Evoque: Drive Pinion Front Bearing

Special Tool(s)

100-012
Slide Hammer

205-067
Preload Gauge

308-615
Remover, Seals

JLR-205-972
Mounting Bracket, Rear Axle

JLR-205-984
Remover/Installer, Drive Pinion Nut

JLR-205-985
Remover, Drive Pinion Bearing

JLR-205-986
Installer, Drive Pinion Bearing

Removal

1. Raise and support the vehicle.

2. Drain the differential fluid.

Refer to: Differential Draining and Filling (205-02 Rear Drive Axle/Differential, General Procedures).

3. Remove the rear differential.

Refer to: Differential Case - Vehicles With: AWF21 6-Speed Automatic Transmission (205-02 Rear Drive Axle/Differential, Removal and Installation).

Refer to: Differential Case - Vehicles With: M66 6-Speed Manual Transmission AWD (205-02 Rear Drive Axle/Differential, Removal and Installation).

4. Remove the differential casing bolts.

5. Remove the differential case.

6. Remove and discard the differential case seal.

7. Remove the crown wheel assembly.

8. Position the differential assembly in a suitable vice as shown.

9. CAUTION: Make sure the pinion seal recess is not damaged as the seal is removed.

• Using the special tool remove the pinion shaft oil seal.
• Special Tool(s): 308-615, 100-012

10. WARNING: High torque application.

NOTE: The special tool should be turned clockwise to remove the pinion shaft nut.

• Using the special tools remove the pinion shaft nut.
• Special Tool(s): JLR-205-984

11.

• Secure the differential casing to the special tool.
• Position the support bolt to its lowest setting.
• Special Tool(s): JLR-205-972

12. CAUTION: Twisting or damage to the casing may occur if the base plates to support the jig on the press are not used. Using a suitable press remove the differential pinion shaft.

13. Remove and discard the pinion shaft collapsible spacer.

14. Remove the tail bearing inner race.

15.

• Using the special tools remove the pinion shaft tail bearing outer race.
• Special Tool(s): 100-012
• Special Tool(s): JLR-205-985

16. CAUTION: It is essential that absolute cleanliness is observed when working on the rear differential. Always cover any open orifices using lint free non-flocking material to prevent the ingress of foreign matter. Failure to follow this instruction may result damage to the components.

• Remove the differential from the supporting tool.
• Thoroughly clean the pinion shaft paying particular attention to the thread.
• Using a suitable cleaning fluid thoroughly clean the differential casings.

Installation

1. CAUTION: Do not clean or lubricate the new pinion shaft tail bearing, as it is supplied coated with a low friction oil. Failure to follow this instruction will require the pinion shaft tail bearing to be replaced before the differential can be successfully assembled.

• Secure the differential casing to the special tool.
• Using a suitable press and the special tool install the pinion shaft tail bearing outer race.
• Special Tool(s): JLR-205-986

2. Install the new pinion shaft spacer.

3.

• Install the pinion shaft to the differential case.
• Lubricate the pinion head bearing with differential oil.
• Position the support bolt to its highest setting.
• Special Tool(s): JLR-205-986

4. CAUTION: Do not clean or lubricate the new pinion shaft tail bearing, as it is supplied coated with a low friction oil. Failure to follow this instruction will require the pinion shaft tail bearing to be replaced before the differential can be successfully assembled. Using a suitable press and the special tool install the pinion shaft tail bearing inner race.

Special Tool(s): JLR-205-986

5.

• Position the differential assembly in a suitable vice as shown.
• Remove the differential from the supporting tool.

6. WARNING: High torque application.

CAUTIONS:

The special tool should be turned counter clockwise to install the pinion shaft nut.

Do not use air tools to install the nut. Failure to follow this instruction may result in damage to the component.

• Using the special tools install the new pinion nut.
• Tighten to 250 Nm (184 ib. ft).
• Special Tool(s): JLR-205-984

7. CAUTIONS:

Make sure the specified torque to rotate the pinion shaft is not exceeded. If excess preload is applied to the joint the pinion shaft should be removed and a new collapsible spacer, pinion shaft tail bearing, pinion shaft tail bearing cup and pinion nut must be installed.

The pinion shaft should be rotated through two full revolutions by hand before the torque measurement is performed.

• Using the special tool, check the torque required to rotate the pinion shaft. The specified torque is 1.1 Nm +/- 0.2 Nm
• If the specified torque to rotate the pinion shaft is not reached, using the special tools, tighten the pinion flange nut in one degree increments and check the rotational torque after each until the specified torque of 1.1 Nm +/-0.2 Nm is achieved.
• Special Tool(s): 205-067

8. CAUTION: Do not lubricate the pinion oil seal. Using a suitable press, the special tool and adapter install the pinion bearing oil seal.

Special Tool(s): JLR-205-986

9. Install the crown wheel assembly.

10. CAUTIONS:

Make sure the mating faces are clean, failure to follow this instruction may result in damage to the differential.

Make sure the new seal is not twisted when fitting, failure to follow this instruction may result in damage to the differential.

• Install the differential case seal.
• Apply a thin amount of clean differential oil to the new differential casing seal.

11.

• Install the differential casing bolts.
• Torque: 29 Nm

12. Install the rear differential.

Refer to: Differential Case - Vehicles With: AWF21 6-Speed Automatic Transmission (205-02 Rear Drive Axle/Differential, Removal and Installation).

Refer to: Differential Case - Vehicles With: M66 6-Speed Manual Transmission AWD (205-02 Rear Drive Axle/Differential, Removal and Installation).

13. Fill the differential case with fluid.

Refer to: Differential Draining and Filling (205-02 Rear Drive Axle/Differential, General Procedures).

Drive Pinion Seal

Special Tool(s)

100-012
Slide Hammer

205-865
Installer, Differential Pinion Seal

303-538
Remover/Installer, Crankshaft Oil Seal

308-615
Remover, Seals

Removal

1. WARNING: Make sure to support the vehicle with axle stands. Raise and support the vehicle.

2. Remove the active on-demand coupling.

Refer to: Active On-Demand Coupling - Vehicles With: AWF21 6-Speed Automatic Transmission (205-02 Rear Drive Axle/Differential, Removal and Installation).

Refer to: Active On-Demand Coupling - Vehicles With: M66 6-Speed Manual Transmission AWD (205-02 Rear Drive Axle/Differential, Removal and Installation).

3. CAUTIONS:

Take extra care not to damage the edges of the component.

Take extra care not to damage the mating faces. Using the special tool, punch a hole in the oil seals outer edge.

Special Tool(s): 303-538

4. CAUTIONS:

Take extra care not to damage the mating faces.

Be prepared to collect escaping oil. Using the special tools and a self tapping screw, remove the oil seal.

Special Tool(s): 308-615, 100-012

Installation

1. CAUTIONS:

Take extra care not to damage the seal.

Make sure that the area around the component is clean and free of foreign material.

Using the special tool, install the new drive pinion seal.

Special Tool(s): 205-865

2. Install the active on-demand coupling.

Refer to: Active On-Demand Coupling - Vehicles With: AWF21 6-Speed Automatic Transmission (205-02 Rear Drive Axle/Differential, Removal and Installation).

Refer to: Active On-Demand Coupling - Vehicles With: M66 6-Speed Manual Transmission AWD (205-02 Rear Drive Axle/Differential, Removal and Installation).

3. Check and top-up the differential case.

Refer to: Differential Draining and Filling (205-02 Rear Drive Axle/Differential, General Procedures).

Rear Halfshaft Seal

Special Tool(s)

205-863
Installer, Halfshaft Seal

Removal

NOTES:

Left-hand shown, right-hand similar.

Some variation in the illustrations may occur, but the essential information is always correct.

1. WARNING: Make sure to support the vehicle with axle stands. Raise and support the vehicle.

2. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

3. Refer to: Rear Halfshaft LH (205-05 Rear Drive Halfshafts, Removal and Installation).

4. CAUTIONS:

Take extra care not to damage the mating faces.

Take extra care not to damage the edges of the component.

Installation

1. CAUTIONS:

Make sure that the seal is correctly located.

Take extra care not to damage the seal.

Special Tool(s): 205-863

2. Refer to: Rear Halfshaft LH (205-05 Rear Drive Halfshafts, Removal and Installation).

3. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

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