Land Rover Defender 90 110 Workshop Book 1 Rover

							1061 TORQUE WRENCH SETTINGS 
. 
TRANSFER BOX LT230R . 
4-cylinder Petrol and Diesel  engine 
Pinch bolt, operating  arm ...................................... 
Gate plate  to grommet  plate ................................... 
Speedometer  cable retainer .................................... 
Locating  plate to gear  change  housing ....................... 
Cross shaft housing  to front  output  housing ................ 
Gear change  housing ............................................ 
Pivot shaft .......................................................... 
Connecting  rod ................................................... 
Retaining plate intermediate  shaft ........................... 
Front output  housing  cover .................................... 
Gear change  housing ............................................ 
Bracket to extension  housing .................................. 
End cover .......................................................... 
Speedometer housinghear output ............................ 
Bottom  cover to transfer case ................................. 
Front  output  housing  to transfer  case ........................ 
Finger housing  to front  output  housing ...................... 
Mainshaft  bearing housing ..................................... 
Brake drum ............................... 
Gearbox  to transfer  box ........................................ 
Bearing  housing to transfer  gearbox ......................... 
Speedometer  housing to transfer gearbox .................. 
Selector  fork to cross  shaft ..................................... 
Yoke  to selector  shaft high/low ............................... 
Selector  fork high/low to shaft ................................. 
Transmission  brake .............................................. 
Gearbox to transfer  case ........................................ 
Gearbox  to transfer  case ........................................ 
Oil drain  plug ...................................................... 
Differential  case .................................................. 
Differential case rear and shaft  main drive 
214
-wheel  drive ................................................. 
Link arm and cross  shaft lever  to ball  joint ................. 
Transfer  breather ................................................. 
Operating  arm high/low ......................................... 
Output flange ..................................................... 
Oil filler/level plug ............................................... 
Nm 
7- 10 
7- 10 
7- 10 
7- 10 
See note 
5
-7 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 . 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
40 
. 50 
40 
. 50 
40 
. 50 
22 . 28 
22 
. 28 
22 
. 28 
22 
. 28 
65 
. 80 
40 
. 50 
See  note 
25 
. 35 
55 
. 64 
146 
. 179 
66 
. 80 
8- 12 
25 
. 35 
7- 11 
Ibf ft 
5-7 
5-7 
5-7 
5
-7 
4
-5 
16 
. 21 
16 
. 21 
16 1 21 
16 . 21 
16 
. 21 
16 . 21 
16 . 21 
16 . 21 
16 
. 21 
16 
. 21 
16 
. 21 
16 
. 21 
16 . 21 
29 . 37 
29 
. 37 
29 
. 37 
16 
. 21 
16 . 21 
16 
. 21 
16 
. 21 
48 
. 59 
29 
. 37 
19 . 26 
40 
. 47 
108 
. 132 
50 . 60 
6
-9 
19 
. 26 
5
-8 
NOTE:- Studs  to be  assembled  into casings  with sufficient  torque to wind them  fully home.  but this  torque  must not 
exceed  the maximum  figure quoted  for the  associated  nut on final  assembly 
. 
TRANSFER  GEARBOX LT230T . 
4 cylinder  Petrol and Diesel  engine  and VS 
Fixings  securing  mounting  brackets to gearbox ........... 
Pinch  bolt operating  arm ....................................... 
Speedometer  cable retainer .................................... 
speedometer  housing ........................................... 
Front output  housing  to transfer .............................. 
Gate  plate  to grommet  plate ................................... 
Bearing housing to transfer  case .............................. 
Locating  plate to gear  change ................................. 
Bottom  cover to transfer ........................................ 
Front output  housing  to transfer .............................. 
80 . 100 
7- 10 
7- 10 
7- 10 
7- 10 
See  note 
5
-7 
22 
. 28 
22 
. 28 
22 
. 28  59 
. 73 
5-7 
5
-7 
5-7 
5
-7 
4-5 
16 . 21 
16 . 21 
16 
. 21 
4  
						

							TORQUE WRENCH SETTINGS El 
. TRANSFER GEARBOX LT230T - 
4 cylinder Petrol and Diesel engine and V8 (cont.) 
Cross shaft housing  to front  output  housing ................ 
Gcar change ....................................................... 
Gear change ........................................................ 
Connecting  rod ................................................... 
Cross shaft to highAow lever ................................... 
Pivot  shaft to link arm ........................................... 
Anti-rotation  plate intermediate  shaft ....................... 
Front output  housing  cover .................................... 
Pivot bracket  to extension  housing ........................... 
Finger housing  to front  output  housing ...................... 
Mainshaft  bearing housing  to transfer  case ................. 
Brake drum to coupling  flange ................................ 
Gearbox  to transfer  case ............... 
Gearbox  to transfer  case ........................................ 
End cover  bearing  housing  to transfer  case ................. 
Speedometer  housing to transfer ............................. 
Speedometer  housing to transfer ............................. 
Selector  finger to cross shaft (highhow) ..................... 
Selector  fork high/low to shaft ................................. 
Transmission  brake to speedometer  housing .............. 
Gearbox to transfer  case ........................................ 
Oil drain plug ...................................................... 
Transfer  case assembly .............. .............. 
Detent  plug ........................................................ 
Differential  casings .............................................. 
Front and rear  out flange ....................................... 
Differential  case rear ............................................ 
Oil filler  and level  plug transfer ............................... 
Transfer  breather ................................................. 
Inter shaft  stake  nut .............................................. 
Nm lbf ft 
22 . 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
22 
. 28 
40 
. 50 
40 . 50 
40 . 50 
40 . 50 
40 . 50 
22 . 28 
22 
. 28 
65 . 80 
40 
. 50 
16 . 21 
16 
. 21 
16 
. 21 
16 
. 21 
16 
. 21 
16 
. 21 
16 
. 21 
16 
. 21 
16 
. 21 
16 . 21 
16 
. 21 
16 
. 21 
29 
. 37 
29 
. 37 
29 
. 37 
29 
. 37 
29 
. 37 
16 
. 21 
16 
. 21 
48 
. 59 
29 
. 37 
See  note 
Plug  to be  coated  with Hylomar  and peened 
. 
Screw  plug fully  in (spring  solid) then turn two 
complete  turns back 
. 
25 . 35  19 . 26 
55 . 64 
146 
. 179 
66 
. 80 
25 
. 35 
7- 11 5-8 
130 
. 140 
40 . 47 
108 
. 132 
50 . 59 
19 
. 26 
96 
. 104 
NOTE:- Studs  to be  assembled  into casings  with sufficient  torque to wind  them  fully home.  but this  torque  must not 
exceed  the maximum  figure quoted  for the  associated  nut on final  assembly . 
GEARBOX AND TRANSFER  BOX LT95 . V8 Petrol engine 
Bell housing  to cylinder  block bolts .......................... 
Gearbox  casing to bell  housing 2 off ......................... 
Gearbox  casing to bell housing  2 off ......................... 
Gearbox  casing to bcll housing stud and nuts .............. 
36, 6 . 44,  8 
1463 . 179 
85,  4 
. 104,  4 
Gearbox  casing to bell  housing  nuts 
.......................... 85, 4 . 104, 4 
146, 
5 . 179 
Output  flange 
-rear - nut and  bolts ....................... 43, 4 . 513 
Output  shaft -rear - nut ..................................... 146, 5 . 179 
Output  shaft 
- front - nut .................................... 146, 5 . 179 
Gear  selector  spherical  scat bolts 
............................. 13, 6 . 16,  3 
43,  4 
. 51, 5 
9, 9 . 11,  9 
Propeller 
shaft 
to flange bolts ................................. 
All other nuts and  bolts: 
M6 
................................................................ 
M8 ................................................................ 23:7 . 29.7 
M10 ............................................................... 48 . 58  27 
. 33 
108 
. 132 
63 
. 77 
63 
. 77 
108 . 132 
32 . 38 
108 . 132 
108 
. 132 
10- 12 
32 
. 38 
7.3 
. 8.7 
17.5 
. 21.3 
35.4 
. 42.8 
5  
						

							I06 I TORQUE WRENCH SETTINGS 
FRONT AXLE 
Brake disc to hub ................................................. 
Brake caliper  to swivel  pin housing .......................... 
Upper  swivel pin to swivel  pin housing ...................... 
Lower  swivel pin to swivel pin housing ...................... 
Swivel  bearing  housing  to axle  case .......................... 
Crown  wheel to differential  case .............................. 
U/J flange to prop  shaft ......................................... 
Mudshield  to swivel pin  housing .............................. 
Bevel pinion  nut .................................................. 
Hub driving  member  to hub ................................... 
Stub  axle to swivel pin  housing ................................ 
Oil seal  retainer  to swivel  pin housing ....................... 
Pinion  housing  to axle  case ..................................... 
Differential  bearing cap to pinion  housing ................. 
Nm 
60-70 
65 
. 80 
60 
. 70 
120 
. 150 
60 
. 70 
22 
. 28 
7
- 10 
65 
. 80 
36 . 46 
55 
. 61 
80 
. 100 
41 
-52 
7
- 10 
95 
. 163 
REAR  AXLE AND FINAL  DRIVE 
Crown wheel to differential  case .............................. 
Rear cover  to axle  case .......................................... 
U1J flange to prop  shaft ......................................... 
Drum to hub ....................................................... 
Rear  brake  assembly  and stub  axle rear to axle  case ..... 
150 . 170 
20 
. 27 
125 
. 142 
41 
. 52 
15 
. 20 
60 
. 70 
60 
. 70 
. Ball  joint  mounting  bracket to axle  case .................... 
Hub  driving  member to hub ................................... 
PROPELLER SHAFTS 
Coupling  flange bolts ............................................ 43 - 51 
REAR  SUSPENSION 
Bottom  link to chassis  nut ...................................... 
Bottom  link to mounting  rubber nuts ........................ 
Top link bracket  to chassis  nuts ............................... 
Bump stop rubber  bracket  nuts ............................... 
Shock absorber  bracket to chassis nuts ...................... 
Shock absorber  upper attachment  to bracket .............. 
Anti  roll bar bush  to chassis  nuts .............................. 
Upper link ball joint  to axle  castle nut ....................... 
Anti  roll bar ball  joint  castle  nut .............................. 
Shock  absorber  lower attachment nuts ...................... 
176 
64 
47 
32 
64 
82 
24 
176 
40 
75 
STEERING  AND FRONT  SUSPENSION 
Tie bar  to mounting  arm nut ................................... 
Mounting  arm to chassis  nuts .................................. 
Tie bar to steering  box nuts .................................... 
Panard  rod to anchor  bracket  nut ............................. 
Panard rod mounting  bracket to chassis  bolts .............. 
Drop arm to drag  link castle  nut .............................. 
Steering  damper to drag  link nut .............................. 
Drop  arm to steering  box nut .................................. 
Radius  arm to axle nuts ......................................... 
Steering  box to chassis  nuts .................................... 
Radius arms to chassis  nuts .................................... 
Track rod ciamp boit nuts ...................................... 
Drag  link clamp  bolt nuts ....................................... 
Steering  wheel retaining  nut ................................... 
Road wheel  nuts .................................................. 
Collapsible  coupling nuts ...................................... 
Panard rod to mounting  arm nut .............................. 
Ball joint  nuts ..................................................... 
81 
176 
81  176 
176 
81 
50 
176 
176 
81  176 
14 
38  108 
41 
45 
115 . 130 
14 
Ibf ft 
44 . 52 
48 
. 59 
44
-52 
88 
. 111 
44 . 52 
16 
. 21 
5
-7 
48 
. 59 
26 
. 34 
40 . 45 
54 
. 74 
30 
. 38 
5
-7 
70 
. 120 
111 . 125 
15 
. 20 
92 
. 105 
30 
. 38 
11 . 15 
44
-52 
44 
. 52 
32 
. 38 
130 
47 
35 
24 
47 
60 
18 
130 
30 
55 
60  130 
60  130 
130 
85 
. 96 
60 
37 
130 
130 
60  130 
10 
10 
28 
80 
30 
33 
... t . k- 
($??; 
.. 
6  
						

							TORQUE WRENCH SETTINGS El 
BRAKES 
Brake disc to hub ................................................. 
Brake  caliper to  swivel housing ............................... 
Brake pipe connections  to: 
P.D.W.A.  valve 
............................................... 9- 11 
Servo, primary port ........................................... 9 . 11 
Servo. secondary  port ........................................ 20 . 24 
Jump  hose 
- female., ........................................ 11 . 13, 5 
6. 8 . 9. 5 
65 . 80 
120 . 150 
Wheel  cylinders ................................................ 
ELECTRICAL  EQUIPMENT . V8 engine 
Alternator: 
Shaft nut 
......................................................... 
Through  bolts .................................................. 
Rectifier  bolts .................................................. 
Starter motor to engine bolts .................................. 
Starter  motor: 
Through  bolts 
.................................................. 
Solenoid  fixing stud nut ...................................... 
Solenoid upper  terminal nut 
.. Reverse light switch .............................................. 
. . ................................ I . 
27. 2 . 473 
4. 5 . 6. 2 
3.  4 
. 3.  96 
40. 6 . 47. 4 
10. 8 
6 
4 
20 . 27 
Lucas 35 DM8 Electronic  ignition distributor V8 engine 
Pick up bearing  plate support  pillars ......................... 1 . 0 . 1.2 
Pickupbarrelnuts 
............................................... 1.1 -1.5 
ELECTRICAL  EQUIPMENT . 4-cylinder Petrol 
and  Diesel  engine 
Alternator: 
Shaft  nut 
......................................................... 
Through  bolts .................................................. 
Rectifier  bolts .................................................. 
Heater plugs -Diesel .......................................... 
Starter motor  to engine ......................................... 
Petrol  models: 
Starter  through bolts 
.......................................... 
Diesel models: 
Solenoid  to starter  nuts 
...................................... 
Solenoid  outer terminal  nuts ................................ 
Starter yoke terminal  outer nut ............................ 
Starter  through bolts .......................................... 
Starter earth stud nut ......................................... 
Eccentric  pivot pin locknut .................................. 
... ... .. 
27. 2 . 47. 5 
4. 5 . 6. 2 
3. 
4 . 3. 96 
15 
. 30 
40 . 50 
10. 8 
6 
4 
2 
10. 8 
8 
21 
48 . 59 
88 . 111 
7
-8 
7
-8 
15 . 18 
8-10 
5-7 
20 
. 35 
3.3 
. 4.6 
2.5 
. 2.9 
30 
. 35 
8.0 
4.5 
3.0 
15 . 20 
9
-11 
10 
. 12 
20 . 35 
3.3 . 4.6 
2.5 
. 2.9 
11 -22 
30 
. 36.8 
8 
4.5 
3  1.5 
8 
6 
16 
7  
						

							GENERAL FI~ING INSTRUCTIONS 
GENERAL FITTING INSTRUCTIONS 
- 
07 
PRECAUTIONS AGAINST DAMAGE 
1. Always fit covers  to protect  wings before 
commencing  work in engine  compartment. 
2. Cover  seats and carpets,  wear clean  overalls  and 
wash  hands 
or wear gloves  before  working  inside 
car. 
3. Avoid  spilling  hydraulic  fluid or battery acid on 
paint  work.  Wash 
off with water  immediately if this 
occurs.  Use Polythene  sheets in boot  to protect 
carpets. 
4. Always  use a recommended  Service Tool, or a 
satisfactory  equivalent, where specified. 
5. Protect  temporarily  exposed screw threads  by 
replacing  nuts or fitting  plastic  caps. 
SAFETY  PRECAUTIONS 
1: 
2. 
3. 
4. 
5. 
6. 
7. 
8. 
9. 
10. 
11. 
Whenever  possible use a ramp  or pit  when  working 
beneath  vehicle, in preference  to jacking.  Chock 
wheels  as well  as applying  hand brake. 
Never  rely 
on a jack  alone  to support  vehicle. Use 
axle stands  or blocks  carefully  placed at jacking 
points  to provide  rigid location. 
Ensure  that a suitable  form of fire  extinguisher  is 
conveniently  located. 
Check  that any lifting  equipment 
uscd has 
adequate  capacity and 
is fully serviceable. 
Inspect  power leads of any  mains  electrical 
equipment  for damage  and check  that it is  properly 
earthed. 
Disconnect  earth (grounded)  terminal of vehicle 
battery. 
Do not  disconnect  any pipes  in air  conditioning 
refrigeration  system, if fitted,  unless  trained  and 
instructed  to do 
so. A refrigerant  is used  which  can 
cause  blindness  if allowed  to contact  eyes. 
Ensure  that adequate  ventilation  is provided  when 
volatile  degreasing  agents are being  used. 
WARNING:  Fume extraction  equipment must be in 
operation  when  trachloride,  methylene chloride, 
chloroform 
or perchlorethylene  are  used for 
cleaning purposes. 
Do not  apply  heat in an  attempt  to free  stiff  nuts  or 
fittings;  as well  as causing  damage  to protective 
coatings,  there is a risk 
of damage  to electronic 
equipment  and brake  lines from  stray heat. 
Do not leave  tools,  equipment,  spilt oil etc., 
around  or 
on work area. 
Wear  protective  overalls and use barrier  creams 
when  necessary. 
PREPARATION 
1. 
2. 
3. 
4. 
5. 
6. 
7. 
Before  removing  a component,  clean it and  its 
surrounding  areas as thoroughly  as possible. 
Blank  off any  openings  exposed by component 
removal,  using greaseproof  paper and masking 
tape. 
Immediately  seal fuel,  oil or hydraulic  lines when 
separated,  using plastic  caps 
or plugs, to prevent 
loss of fluid  and entry  of dirt. 
Close  open ends of oilways,  exposed  by component 
removal,  with tapered  hardwood  plugs 
or readily 
visible  plastic  plugs. 
Immediately  a component  is removed,  place 
it in a 
suitable  container;  use a separate  container  for 
each  component  and its associated  parts. 
Before  dismantling  a component,  clean it 
thoroughly  with a recommended  cleaning agent; 
check  that agent  is suitable  for all materials  of 
component.  Clean  bench  and provide  marking  materials, 
labels,  containers  and locking  wire before 
dismantling  a component. 
DISMANTLING 
1. 
2. 
3. 
4. 
5. 
6. 
Observe  scrupulous  cleanliness  when dismantling 
components,  particularly when brake,  fuel or 
hydraulic  system parts are being  worked 
on. A 
particle  of dirt 
or a cloth  fragment  could cause a 
dangerous  malfunction  if trapped  in these  systems. 
Blow  out all tapped  holes, crevices,  oilways and 
fluid  passages  with an air  line.  Ensure  that any 
0
-rings  used for sealing  are correctly  replaced or 
renewed,  if disturbed. 
Mark  mating  parts to ensure  that they  are replaced 
as  dismantled.  Whenever possible use marking  ink, 
which  avoids  possibilities 
of distortion  or initiation 
of cracks,  liable if centre punch  or scriber  are used. 
Wire  together  mating parts where  necessary  to 
prevent  accidental  interchange  (e.g. roller  bearing 
components).  Wire  labels  on to all  parts  which  are to be  renewed, 
and  to parts  requiring  further inspection  before 
being  passed  for reassembly;  place these parts in 
separate  containers  from those containing  parts for 
rebuild. 
Do not  discard  a part  due for renewal  until after 
comparing  it with  a new  part,  to  ensure that its 
correct  replacement  has been  obtained. 
1  
						

							1051 GENERAL FITTING INSTRUCTIONS 
INSPECTION - GENERAL 9. When fitting bearing  to shaft,  apply force only to 
inner  ring of bearing,  and only  to outer  ring when 
fitting  into housing. 
1. Never  inspect  a component  for wear  or 
dimensional  check unless 
it is absolutely  clean; a 
slight  smear  of grease  can conceal  an incipient 
failure. 
2. When  a component  is to  be  checked  dimensionally 
against  figures quoted  for it, use  correct  equipment 
(surface  plates, micrometers,  dial gauges,  etc.) in 
serviceable  condition. Makeshift checking 
equipment  can be dangerous. 
3. Reject  a component  if its  dimensions  are outside 
limits  quoted,  or 
if damage is apparent.  A part 
may,  however,  be refitted  if its  critical  dimension  is 
exactIy limit size, and is otherwise  satisfactory. 
4. Use ‘Plastigauge’ 12 Type PG-1 for checking 
bearing  surface clearances;  directions for its use, 
and  a scale  giving  bearing  clearances  in 
0,0025 mm 
(0.0001 in) steps  are provided  with it. 
BALL AND ROLLER BEARINGS 
NEVER  REPLACE A BALL OR ROLLER 
BEARING  WITHOUT  FIRST ENSURING  THAT 
1. Remove all traces of lubricant  from bearing  under 
inspection  by washing  in petrol 
or a suitable 
degreaser;  maintain absolute cleanliness 
throughout  operations. 
2. Inspect visually  for markings of any  form on rolling 
elements,  raceways,  outer surface 
of outer rings or 
inner  surface 
of inner  rings.  Reject  any bearings 
found  to be  marked,  since any marking  in these 
areas  indicates  onset of wear. 
3. Holding  inner race between  finger and thumb of 
one hand,  spin outer  race and check  that it revolves 
absolutely  smoothly. Repeat, holding outer race 
and  spinning  inner race. 
4. Rotate  outer ring gently  with a reciprocating 
motion,  while holding  inner ring; 
feel for any  check 
or  obstruction 
to rotation,  and reject  bearing if 
action is not  perfectly  smooth. 
5. Lubricate  bearing generously  with lubricant 
appropriate  to installation. 
6. Inspect  shaft and bearing  housing  for 
discolouration  or other  marking  suggesting  that 
movement  has taken  place between  bearing and 
seatings.  (This is particularly  to be  expected 
if 
related  markings  were found  in operation 2.) If 
markings  are found,  use ‘Loctite’  in installation 
of 
replacement  bearing. 
7. Ensure that shaft  and housing  are clean  and free 
from  burrs  before  fitting bearing. 
8. If one  bearing of a pair  shows  an imperfection it is 
generally  advisable  to renew  both bearings:  an 
exception  could be made 
if the faulty  bearing  had 
covered  a low  mileage,  and 
it could be established 
that  damage  was confined  to it only. 
IT 
IS IN 
AS-NEW  CONDITION. 
ST1042M ‘\U 
10. In the  case  of grease-lubricated  bearings (e.g. hub 
bearings) 
fill space  between  bearing and outer  seal 
with  recommended  grade 
of grease before fitting I 
11. Always  mark components of separable  bearings +--* 
(e.g. taper  roller  bearings)  in dismantling,  to 
ensure  correct  reassembly.  Never fit new  rollers 
in 
a used  cup. 
-_ 
seal. fa 
OIL SEALS 
1. Always  fit new  oil seals  when  rebuilding  an 
assembly.  It is not  physically  possible to replace  a 
seal  exactly  when it has  bedded  down. 
2. Carefully  examine seal before  fitting to ensure  that 
it  is  clean  and undamaged. 
3. Smear  sealing  lips with  clean  grease;  pack dust 
excluder  seals with grease,  and heavily  grease 
duplex  seals 
in cavity between  sealing lips. 
4. Ensure  that seal spring,  if provided,  is correctly 
fitted. 
5. Place  lip of seal towards  fluid to be  sealed  and slide 
into  position 
on shaft,  using fitting  sleeve when 
possible  to protect  sealing lip from  damage  by 
sharp  corners,  threads or splines.  If fitting  sleeve  is 
not  available,  use plastic  tube 
or adhesive  tape to 
prevent  damage 
to sealing lip. 
&*: %L;’ 
ST 1 038 M WLJ 
2  
						

							GENERAL FITTING INSTRUCTIONS 10711 
-= 
>. 
6. Grease outside  diameter  of seal,  place  square  to 
housing  recess and press  into position,  using great 
care  and 
if possible  a ‘bell  piece’  to ensure  that seal 
is  not  tilted.  (In some  cases it may  be preferable  to 
fit  seal  to housing  before fitting to shaft.)  Never let 
weight  of unsupported  shaft rest in seal. 
9 .I 
ST1037M 
7. If correct  service tool is not  available,  use a suitable 
drift  approximately  0,4 
mm (0.015 in) smaller  than 
outside  diameter 
of seal. Use a hammer  VERY 
GENTLY on drift if a press  is not  suitable. 
8. Press  or drift  seal in to  depth  of housing if housing 
is  shouldered,  or flush  with face of housing  where 
no  shoulder  is provided.  Ensure that the seal  does 
not  enter  the housing  in a tilted  position. 
NOTE: Most cases of failure  or  leakage of oil seals 
are due  to  careless  fitting,  and  resulting damage to 
both  seals  and  sealing  surfaces.  Care in fitting 
is 
essential  if good results  are to be  obtained. 
JOINTS AND JOINT FACES 
1. Always  use correct  gaskets  where they are 
spccificd. 
2. Use jointing  compound  only when  recommended. 
Otherwise 
fit joints  dry. 
3. When  jointing  compound  is used,  apply  in a thin 
uniform  film to metal  surfaces;  take great  care to 
prevent 
it from  entering  oilways, pipes or blind 
tapped  holes. 
4. Remove  all traces of old  jointing  materials  prior to 
reassembly. 
Do not  use a tool  which  could damage 
joint  faces. 
5. Inspect  joint faces  for scratches  or burrs  and 
remove  with a fine 
file or  oil  stone;  do not  allow 
swarf  or dirt  to enter  tapped  holes or enclosed 
parts. 
6. Blow  out any  pipes,  channels  or crevices  with 
compressed  air, renewing 
any 0
-rings  or seals 
displaced  by air  blast. 
FLEXIBLE HYDRAULIC PIPES, HOSES 
1. Before  removing  any brake  or power  steering  hose, 
clean  end fittings  and area  surrounding  them as 
thoroughly  as possible. 
2. Obtain  appropriate  blanking caps before  detaching 
hose  end fittings, 
so that  ports  can be immediately 
covered  to exclude  dirt. 
3. Clean hose externally  and blow  through  with 
airline.  Examine  carefully for cracks,  separation  of 
plies,  security 
of end fittings  and external  damage. 
Reject  any hose  found 
faulty. 
4. When  refitting  hose, ensure  that no unnecessary 
bends  are introduced,  and that  hose  is 
not twisted 
before  or during  tightening  of union  nuts. 
5. Containers  for hydraulic  fluid must  be kept 
absolutely  clean. 
6. Do not store  hydraulic  fluid in an  unsealed 
container.  It will  absorb  water, and fluid 
in this 
condition  would be dangerous  to use  due  to a 
lowering  of its  boiling  point. 
7. Do not allow  hydraulic  fluid to be  contaminated 
with  mineral  oil, or use  a container  which has 
previously  contained mineral oil. 
8. Do not re-use  fluid  bled from  system. 
9. Always  use clean  brake  fluid to clean  hydraulic 
components. 
10. Fit  a blanking  cap to a hydraulic  union and a plug 
to  its  socket  after removal  to prevent  ingress 
of 
dirt. 
11. Absolute  cleanliness  must be observed  with 
hydraulic  components  at all  times. 
12. After  any work  on hydraulic  systems, inspect 
carefully  for leaks  underneath  the vehicle  while a 
second  operator  applies maximum  pressure to the 
brakes  (engine  running)  and operates  the steering. 
METRIC BOLT IDENTIFICATION 
1. An IS0 metric  bolt or screw,  made of steel  and 
larger  than 
6 mm in diameter  can be identified  by 
either  of the  symbols 
IS0 M or M embossed  or 
indented 
on top  of the  head. 
2. In addition  to marks  to identify  the manufacture, 
the  head  is also  marked  with symbols  to indicate 
the  strength  grade 
e.g. 8.8, 10.9, 12.9 or 14.9, 
where the first  figure  gives the minimum  tensile 
strength 
of the  bolt  material  in tens  of kg/sq mm. 
3. Zinc  plated IS0 metric  bolts and nuts  are chromate 
passivated,  a greenish
-khaki  to gold-bronze  colour. 
ST1035M 3  
						

							1071 GENERAL FIITING INSTRUCTIONS 
1. 
2 
3. 
~~__ ~~ 
METRIC NUT IDENTIFICATION 
A A nut 
with  an IS0 metric thread  is marked  on one 
face  or on  one  of the  flats  of the  hexagon  with the 
strength  grade symbol 
8,12 or 14. Some  nuts with a 
strength  4, 5 or 6 are also  marked  and some  have 
the  metric  symbol 
M on the  flat opposite the 
strength  grade marking. 
A clock  face system  is used  as an  alternative 
method  of indicating  the strength  grade. The 
external  chamfers  or a face 
of the  nut is marked  in 
a  position  relative to the  appropriate  hour mark  on 
a  clock  face to indicate  the strength  grade. 
A dot is used  to locate  the 12 oclock  position and a 
dash  to indicate  the strength  grade. If the  grade 
is 
above  12, two  dots  identify  the 12 oclock position. 
1 2 m 
STl036M 
HYDRAULIC FITTINGS - Metrication 
WARNING:  Metric  and Unified  threaded  hydraulic 
parts.  Although  pipe connections to  brake system units 
incorporate  threads  of  metric  form, 
those for  power 
assisted steering are of  UNF type.  It 
is vitally important 
that  these  two thread  forms are  not  confused,  and 
careful study should be  made 
of the following notes. 
Metric  threads  and metric  sizes are being  introduced 
into  motor  vehicle  manufacture  and some  duplication 
of  parts  must be expected.  Although standardisation 
must  in the  long  run be good, 
it would  be wrong  not to 
give  warning  of the  dangers  that exist  while  UNF and 
metric  threaded  hydraulic  parts continue  together in 
service.  Fitting UNF pipe nuts into metric  ports and 
vice
-versa  should  not happen,  but experience  of the 
change  from BSF 
to UNF indicated  that there  is no 
certainty  in relying  upon the difference 
in thread  size 
when  safety  is involved. 
To  provide  permanent  identification  of metric  parts is 
easy hut recognitinn has been assistpd h
 J the 
following  means. (Illustration A Metric, B Unified.) 
1. 
2. 
3. 
4 
U 
@B 
ST1033M 
A B 
ST1034M 
The metric  female  nut is always used with a trumpet 
flared  pipe and the metric  male nut is 
always used  with 
a  convex  flared pipe. 
4. 
AI1 metric  ports in cylinders  and calipers  have no 
counterbores,  but unfortunately  a few  cylinders 
with  UNF  threads  also have  no counterbore.  The 
situation  is, all  ports  with counterbores  are UNF, 
but  ports  not counterbored  are most  likely  to be 
metric. 
5. The  colour of the protective  plugs in hydraulic 
ports  indicates  the size  and  the type  of the  threads, 
but  the function  of the  plugs  is 
protcctive and not 
designed  as positive  identification. 
In production it 
is difficult to use the wrong  plug but human  error 
must  be taken  into account. 
The  Plug  colours  and thread  sizes are: 
UNF 
RED 
iinx24UNF 
GREEN 6 in x 20 UNF 
YELLOW 
4 in x 20 UNF 
PINK 
B in x 18 UNF 
METRIC 
BLACK 
1Ox 1 mm 
GREY  12x1 mm 
BROWN  14 x 1,5 mm 
6. Hose ends  differ  slightly  between  metric and UNF. 
Gaskets  are not  used  with metric  hoses. The UNF 
hose  is sealed 
on the  cylinder  or caliper  face by a 
copper  gasket by the  metric  hose seals  against  the 
bottom  of the  port  and there  is a gap  between  faces 
of the hose  and cylinder. 
Pipe  sizes  for UNF  are 
& in, in and & in outside 
diameter. 
Metric  pipe sizes  are 4,75 mm, 6 mm and 8 mm. 
c- 
.. All metric  pipe nuts,  hose ends,  unions  and bleed 
screws  are coloured  black. 
letter 
M. 
Metric  and UNF  pipe nuts are slightly  different  in 
shape. 
4,75 mm pipe  is exactly  the same  as + in pipe. 
6 mm pipe  is 0.014 in smaller  than i in pipe. 8 mm 
Convex  pipe flares  are shaped  differently  for f J 
metric sizes and when  making  pipes for metric 
equipment,  metric pipe flaring  tools must be used. 
The 
hexagon  area 
of pipe nuts is indented  with the 
pipe is 0.002  in larger  than & in pipe. -.  
						

							GENERAL FITTING INSTRUCTIONS Ei 
ST1031 M 
ST1032M 
The greatest  danger lies  with  the  confusion  of 
10 mm and 2 in UNF pipe nuts used for in (or 
4,75 mm) pipe.  The 3 in UNF pipe nut or hose  can 
be  screwed  into a 
10 mm port  but is very  slack  and 
easily  stripped.  The thread  engagement  is very 
weak  and cannot  provide  an adequate  seal. 
The  opposite  condition,  a 
10 mm nut in a  in port, 
is difficult  and unlikely  to cause trouble. The 10 mm 
nut will  screw  in 1; or 2 turns and seize.  It has  a 
crossed  thread ‘feel’ and it 
is impossible  to force  the 
nut  far enough  to seal  the pipe.  With  female  pipe 
nuts  the position  is of  course  reversed. 
The  other  combinations  are 
so different that there  is 
no  danger 
of confusion. 
KEYS AND KEYWAYS 
-- 
,’ 1. Remove  burrs  from  edges of keyways with a fine 
file  and clean thoroughly  before attempting  to refit 
key. 
2. Clean  and  inspect  key  closely; keys are suitable for 
refitting  only if indistinguishable  from new, as any 
indentation  may indicate  the onset  of wear. 
TAB  WASHERS 
1. Fit new washers in all places  where  they  are used. 
2. Ensure  that the new  tab washer  is of the same 
Always 
renew a used  tab washer. 
design as  that replaced. 
SPLIT PINS 
ST1030M 
NUTS 
1. When  tightening  a  slotted or castellated  nut  never 
slacken 
it back to insert  split  pin  or locking  wire 
except  in those  recommended  cases where  this 
forms  part 
of an adjustment.  If difficulty  is 
experienced,  alternative washers or nuts 
should be 
selected,  or washer  thickness reduced. 
2. Where  self-locking  nuts  have been removed it is 
advisable  to replace  them  with new ones 
of the 
same type. 
NOTE: Where  bearing  pre-load is involved  nuts 
should  be tightened  in accordance  with  special 
instructions. 
LOCKING WIRE 
1. Fit  new  locking wire of the  correct  type for all 
2. Arrange wire so that its tension tends  to tighten  the 
assemblies incorporating 
it. 
bolt 
heads, or nuts, to which it is  fitted. 
SCREW  THREADS 
1. Both UNF and Metric  threads to IS0 standards are 
used.  See below  for thread  identification. 
2. Damaged thrcads must always  be  discarded. 
Cleaning 
up threads  with a die or tap  impairs  the 
strength  and  closeness of fit  of the  threads  and  is 
not 
recommcndcd. 
3. Always  ensure  that  replacement  bolts are  at  least 
equal 
in strength to those rcplaced. 
4. Do  not  allow  oil,  grease  or jointing  compound  to 
enter  blind threaded  holes. The hydraulic  action on 
screwing 
in the bolt  or stud  could split  the housing. 
5. Always tighten a nut or bolt to the  recommended 
torque  figure.  Damaged  or corroded  threads 
can 
affect the torque  reading. 
6. To check or re-tighten a bolt or screw to a specified 
torque  figure,  first slacken a  quarter 
of a turn,  then 
re
-tighten  to the correct figure. 
7. Always  oil thread  lightly before  tightening to 
ensure a free  running  thread, except in the  case  of 
self
-locking  nuts. 
1. Fit new split  pins  throughout  when replacing  any 
unit. 
2. Always fit split pins  where split pins were  originally 
used. 
Do not  substitute  spring washers:  there is 
always  a good reason for 
the use of a split pin. 
3. All  split  pins should  be fitted  as shown  unless 
otherwise  stated. 
. 7: ... .. ::. ;a ... , . ... 
5  
						

							. 
1071 GENERAL FITTING INSTRUCTIONS 
1. 
2. 
3. 
UNIFIED  THREAD  IDENTIFICATION 
Bolts 
A circular recess is stamped  in the  upper  surface of 
the bolt  head. 
Nuts 
A continuous  line of circles is indented  on  one of 
the flats of the hexagon,  parallel to the  axis of the 
nut. 
Studs, Brake Rods, etc. 
The  component is reduced to the core  diameter for 
a short length  at its extremity. 
.. 
ST1039M ‘2 
6