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Home > Technical (L322) > Getting ready to overhaul L322 BMW era front diff

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kanikune

Member Since: 29 Oct 2017
Location: Teerijarvi
Posts: 28

2004 Range Rover Vogue 4.4 V8 Epsom Green

Getting ready to overhaul L322 BMW era front diff

I've been having some time what I believe is front differential whine.
So, to beat the bullet I ordered used differential from the ebay.
The idea is to overhaul this unit to perfection and then install the unit into the car.

So far the with process:

Dismantled the differential, so no turning back.

Laser cut some metal plates.

Last night was able to peel of the bearings from the pinion and the crown wheel (?).

Click image to enlarge

with the help of this set.

First took out the outer cages of the bearings. Taking a grip of the inner body of the bearing was easier job. They are super tigtht!

If you are wondering, what the laser cut plates are doing, they are for the assembly process.
This is copied directly from the manual. With this stand bearing cup can be bench pressed and also this unit can be secured to the bench vice easily to make the super accurate tightening of the pinion nut easier to manage.
I have the torque dial wrench ready, as I do with complete bearing and gasket set not to forget crush sleeve.

Click image to enlarge

18th May 2023 5:19pm

Haylands

Member Since: 04 Mar 2014
Location: East Yorkshire
Posts: 8195

2014 Range Rover Autobiography SDV8 Loire Blue

Excellent work, that should save you some money... Pete

__________________________________________________
2014 L405 Autobiography SDV8 4.4 Loire Blue Ebony interior
2011 L322 Vogue SE 4.4 TDV8 Baltic Blue. Parchment over Navy Interior. Sold
2012 L322 Autobiography 5.0 Supercharged Ipanema Sand, Jet Interior. Sold
2002 L322 Vogue 4.4 V8 Epson Green, Ivory over Aspen Interior (Fatty Offroader) Sold
-Click for Project Fatty off roader-

19th May 2023 7:17am

RRPhil

Member Since: 22 Aug 2011
Location: Blackburn, Lancashire
Posts: 963

Great stuff. I’m sure you already have a copy of the Q041 Service Action (definitely-not-a-recall) rebuild procedure, but it’s here, just in case :

https://www.fullfatrr.com/forum/post529425.html#529425

Phil

19th May 2023 3:01pm

kanikune

Member Since: 29 Oct 2017
Location: Teerijarvi
Posts: 28

Small progress and I don't know yet if this was success, but thoughts so far..
Pinion has 48.5 -> ~ 49 mm slots for getting grip of the pinion.

New bearings and old shims in place, you cannot tighten the pinion nut easily to the point, where side play of the bearings have been eliminated. This means that it is quite easy to ruin the oil seal of the pinion.
You need massive force to overcome the crush sleeve. Manual says that crush sleeve requires 8-10 tonnes to alter shape. What this meant in real life?
I had to have 1.5 meter leverage to turn the nut!

To sum two previous notes I think it is best to assemble everything, put the whole thing hanging from the 49 mm holder from the pinion. Then turn the nut little by little.

Pics to follow sometime soon.

I have the dial gauge for the rotational force, so I was able to check rotational force as per manual suggests.

11th Jul 2023 11:20am

kanikune

Member Since: 29 Oct 2017
Location: Teerijarvi
Posts: 28

Here's the progress.
Took the angle grinder and cut 49 mm slot to the laser cut frame

After the slack of the bearing was tightened off, the whole unit was lifted to table and while rotating the meter once per second, force was read. This process was iterarated three times and the 1.5Nm force was there. The bearing actually tightens quite fast. Small increments should be done.

I test assembled the unit with crown wheel and almost zero slack can be felt in the pinion. Seems promising so far.

14th Jul 2023 6:32pm

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