Land Rover Defender 90 110 Workshop Book 4 Rover

							Section 
Number 
70 
57 STEERING 
BRAKING SYSTEM 
CONTENTS 
Page 
-Overhaul manual steering  box 
-Overhaul steering  column 
-Overhaul power steering box 
-Bleeding  power steering  system 
-Test power steering  system 
-Adjust power  steering  box 
- Overhaul  power steering  pump - V8 engine vehicles - early models 
- Overhaul Adwest  lightweight power steering  box 
- Bleeding Adwest lightweight  power steering  box 
-Test Adwest  lightweight power steering  box 
- Adjust Adwest  lightweight  power steering  box 
- Overhaul Gemmer power steering  box 
-Power steering - fault diagnosis 
- Overhaul  drop arm joint 
-Adjusting  track rod and  drag link joints  Adwest 
early models 
I 
I 
164 I SUSPENSION 
1 
3 
8 
16 
16 
18 
18 
20 
30 
30 
31 
32 
43 
44 
46 
- Overhaul front hub  assembly 
-Overhaul stub axle,  axle shaft constant  velocity joint and swivel  assembly 
1 
3 
- Description 
~, -Overhaul  front brake  calipers 
- Overhaul rear brakes - ‘90’ models 
- Overhaul  rear brakes - ‘1 10’ models 
- Overhaul transmission  brake 
- Bleeding brakes 
- Overhaul  master cylinder 
-Fault diagnosis 
n 
I76 I CHASSIS AND BODY 
1 
2 
6 
7 
8 
10 
11 
14 
- Chassis  dimensions - ‘90’ models 
- Chassis  dimensions - ‘110’ models 
- Kemoving  door trim - ‘90’ ana ’iiW 
- Rearside doors  and window mechanisms - ‘90’ and ‘1 10’ 
- Front  doors and window  mechanisms - ‘90’ and ‘1 10’ 
- 
1 
3 
6 
7 
12 
.. 
1  
						

							INTRODUCTION 
This Workshop  Manual  covers  the Land Rover  Ninety  and One  Ten range  of vehicles.  It is primarily  designed  to 
assist  skilled  technicians  in the 
efficient repair  and maintenance of Land Rover  vehicles. 
Using  the appropriate  service tools and carrying  out 
the procedures  as  detailed will enable  the  operations  to  be 
completed 
within the time stated in the Repair Operation Times 
The  Manual  has  been  produced in separate  books; this allows the information to be distributed  throughout  the 
specialist  areas of the modern  service facility. 
A table of contents in Book 1 lists  the major  components  and systems together  with thc section and book  numbers. 
The  cover 
of each  book  details thc sections  contained  within that book. 
The  title page  of each  book  carries the part  numbers  required to order  replacement  books, binders 
or complete 
Service  Manuals. This  can be done  through  the normal  channels. 
REFERENCES 
References to the left- or right-hand  side in the  manual  are  made when viewing  the vehicle  from the rear.  With  the 
engine  and gearbox  assembly 
removcd, the water  pump  end of the  engine  is referred  to as the front. 
To reduce repetition, operations  covered in this  manual  do not include referencc to testing  the vehicle  aftcr rcpair. It 
is essential that  work is inspected and  tested aftcr completion  and if necessary a road  test of the vehicle  is carried  out 6: T 
particularly  where safety relatcd items are concerned.  .t 
DIMENSIONS 
The dimensions  quoted are to design  engineering  specification. Altcrnative unit equivalents,  shown in brackets 
ColJowing the  dimensions, have bccn converted  from the original specification. 
During 
the period  of running-in from new, certain  adjustments  may vary  from  the specification figurcs given in this 
Manual. These  adjustments  will be re
-set  by the Distributor  or Dealer  at the After Sales  Service,  and  thereafter 
should  bc maintained  at the  figures  specified  in the Manual. 
REPAIRS AND REPLACEMENTS 
When replacement  parts are required it is essential  that only Land Rover  parts are used. 
Attcntion is particularly  drawn  to the  following  points  concerning repairs  and  the fitting of replacement  parts  and 
accessories: 
Safety  features  embodied 
in the vehicle  may be impaircd if other  than  Land  Rover  parts  are fitted. In certain 
territories,  legislation prohibits  the  fitting of parts 
not to the vehicle  manufacturers  specification. Torque wrench &++. 
sctting figures given in the Repair  Operation  Manual  must be strictly  adhered to. Locking devices, where specified, ; 
must bc fitted.  If the efficicncy of a locking  device is impaired  during  removal it must be renewed.  Owners 
purchasing  accessories 
while travelling abroad should ensure  that the accessory  and its fitted  location on the vehicle 
conform  to mandatory  requirements  existing in their country  of origin.  The terms 
of the Owners  Service Statement 
may  be 
invalidatcd by the  fitting of other  than Land  Rover parts. 
All Land Rover  parts have the  full backing  of the Owners  Service Statement. 
Land  Rover Distributors  and Dealers are obliged 
to supply only Land Rover  service  parts. 
POISONOUS SUBSTANCES 
Many  liquids  and other  substances  used in motor vehicles  arc poisonous  and  should  under no circumstances  be 
consumed  and  should  as far as  possible  be kept  away  from open  wounds.  These substances among others  include 
antifreeze, brake  fluid, 
fucl, windscreen washer  additives, lubricants  and various  adhesives. 
FUEL HANDLING PRECAUTIONS 
The following  information  provides  basic precautions  which must be observed if petrol  (gasoline)  is to  be  handled 
This information  is issued  for basic  guidance  only, and 
in any case of doubt appropriate enquiries  should be made  of 
your  local  Fire Officer. 
safely. It 
also outlines  the other  areas of risk  which  must not be ignored. g-; = 
I1  
						

							GENERAL 
PetroVgasoline vapour is highly  flammable and  in confined  spaces is also  very  explosive  and toxic. 
When 
petrol/gasoline evaporates  it produces 150 times  its  own  volume in vapour,  which when diluted  with air 
becomes  a  readily ignitable  mixture. The vapour  is heavier  than air and  will  always  fall to the  lowest  level. It can 
readily  be distributed  throughout  a workshop  by air  current,  consequently,  even a small  spillage 
of petrol/gasoline is ... ,  ~ ;;;,:ii.,;:: .... , .C I._..1 .. , .. . ... _ potentially 
very dangerous. 
Always  have a fire extinguisher  containing FOAM 
CO2 GAS, or POWDER  close at hand  when  handling  or draining 
fuel,  or when  dismantling  fuel systems  and in areas  where 
fuel containers  are stored. 
Always disconnect  the vehicle  battery BEFORE  carrying out dismantling  or draining work  on a fuel system. 
Whenever 
petrol/gasoline is  being  handled,  drained or stored,  or when  fuel systems  are being dismantled  all forms of 
ignition must  be extinguished  or removed, any head-lamps used  must be flameproof  and kept clear of spillage. 
NO  ONE  SHOULD  BE PERMITTED 
TO REPAIR  COMPONENTS  ASSOCIATED  WITH  PETROL/ 
GASOLINE  WITHOUT FIRST HAVING  HAD SPECIALIST  TRAINING. 
FUEL TANK DRAINING 
WARNING: PETROL/GASOLINE MUST NOT BE EXTRACTED OR DRAINED  FROM ANY VEHICLE WHILST 
IT IS STANDING  OVER A PIT. 
Draining or extracting petrol/gasoline from vehicle  fuel tank  must  be carried  out in a well  ventilated  area. 
The  receptacle  used 
to contain  the petrol/gasoline must be  more  than adequate for  the  full amount  of  fuel to be 
extracted  or drained.  The receptacle  should be clearly  marked  with  its contents,  and  placed in a  safe  storage  area 
which  meets the requirements 
of local authority regulations. 
WHEN 
PETROL/GASOLINE HAS  BEEN  EXTRACTED OR DRAINED  FROM A FUEL  TANK  THE 
PRECAUTIONS GOVERNING NAKED LIGHTS  AND IGNITION  SOURCES SHOULD BE MAINTAINED. 
FUEL TANK REMOVAL 
On vchiclcs where the fuel  line is secured to the  fuel  tank  outlet  by a spring  steel clip,  it is  recommended  that such 
clips  are 
reieased before  the fuel  line  is disconnected  or the  fuel  tank  unit is removed.  This procedure  will avoid  the 
possibility  of  residual petrol fumes in the  fuel  tank  being ignited  when the clips are released. 
As  an added  precaution  fuel tanks  should  have a 
PETROWGASOLINE VAPOUR  warning label attached  to them 
as 
soon as  they  are removed  from the vehicle. 
FUEL TANK REPAIR 
Under no circumstances should a repair to any  tank  involving  heat treatment be carried  out without  first  rendering 
the  tank  SAFE,  by using  one of the  following  methods: 
STEAMING:  With the filler  cap and  tank unit removed,  empty the tank.  Steam  the tank for at  least two hours 
with  low  pressure steam. Position  the  tank 
so that  condensation  can drain  away  freely, ensuring  that any 
sedimcnt and sludge  not volatised  by the steam, is washed  out during  the steaming  process. 
BOILING:  With the filler  cap and tank  unit removed,  empty the tank. Immerse  the tank  completely  in boiling 
water  containing  an effective  alkaline  degreasing  agent or a detergent,  with the water  filling  and 
also 
surrounding  the tank for at least two hours. 
After  steaming  or boiling 
a signed  and dated  label to this effect should  be attached  to the tank. 
. .. 
SPECIFICATION 
Purchasers  are advised  that the specification  details set out in this Manual apply to a range of vehicles  and not  to any 
one. 
For the  specification  of a particular  vehicle, purchasers  should consult  their Distributor  or Dealer. 
The  Manufacturers  reserve the right  to vary  their  specifications  with or without  notice, and  at such times  and 
in such 
manner as they  think  fit. Major as  well as minor  changes  may be involved  in accordance  with the Manufacturers 
policy 
of constant  product improvement. 
Whilst  every  effort  is made  to  ensure 
the accuracy  of the  particulars  contained in this Manual, ncither thc 
Manufacturer  nor the Distributor or Dealer,  by whom  this Manual  is supplied,  shall in any  circumstances  be  held 
liable  for any  inaccuracy 
or the consequences  thereof. 
COPYRIGHT 
@ Land Rover Limited 1984 
, , . . .. .I ., . . . . ... . . 
.. :  
All rights reserved. No part of this  publication  may be produced,  stored in a retrieval  system  or transmitted in any 
form,  electronic,  mechanical,  photocopying,  recording  or other  means  without  prior written  permission  of Land 
Rover  Limited,  Service Department,  Solihull, England. , .. ,. 
... 111  
						

							. Special Service 
The use of approved  special service  tools  is important.  They  are essential if service 
operations  are to be  carried  out efficiently,  and 
safcly. The amount of time  which  they 
save  can be considerable. 
Every  special  tool 
is designed  with the close  co-operation of Land  Rover  Ltd., and no 
tool  is put  into  production  which has not been  tested  and approved  by us.  New  tools  are 
only  introduced  where  an  operation cannot be satisfactorily  carried out using  existing 
tools 
or standard equipment.  The user is therefore  assured that the tool  is necessary  and 
that it  will perform  accurately,  efficiently and safely. 
Special  tools bulletins  will be issued  periodically  giving  details 
of new tools  as they  are 
introduced. 
All orders  and  enquiries from the United  Kingdom  should  be sent  direct to V. L. 
Churchill.  Overseas orders  should be placed  with the local V. L. Churchill  distributor, 
where  one exists.  Countries  where  there  is no  distributor  may order  direct  from 
V. L. 
Churchill  Limited, 
PO Box 3 Daventry, Northants,  England NNll4NF. 
The tools  recommended  in this  Workshop  Manual are listed  in a multi-language,  illustrated  catalogue 
obtainable  from  Messers. 
V. L. Churchill  at the  above  address  under publication  number 2217/2/84 or from 
Land  Rover  Ltd., under part  number 
LSM0052TC from the following  address,  Land  Rover Merchandising 
Service, 
P.O. Box  534,  Erdington,  Birmingham  B24 OQS.  
						

							STEERING 
GEMMER MANUAL STEERING BOX 
OVERHAUL 
Special tool: 
RO 1016 
Dismantle 
1. Remove  the  steering  box from  the vehicle,  and 
2.  Remove  the adjuster  locknut. 
3.  Remove the  four bolts  securing  the top  cover. 
4.  Unscrew the  top cover  from the adjuster. 
5. Lift  out the sector  shaft. 
6. Remove  the  four bolts  securing  the worm  shaft 
retaining  plate and remove the  plate complete  with 
shims  and joint washer. 
remove 
the drop arm. 
7. Remove the  taper bearing  and track. 
8. Withdraw the  worm shaft and collect  the opposite 
taper  bearing. 
.9.  Drift  out the worm shaft 
oil seal. 
10. Drift  out the shaft-end  bearing track  and collect  the 
shim.  Note since  this shim  or one  of the same  value 
must  be refitted,  as a precaution  against loss, check 
the  thickness  with  a  micrometer  and  note the 
reading. 
11. Prise  out the sector shaft oil seal. 
12.  Drift  out the sector  shaft needle roller bearings. 
Inspection 
13. Clean  and degrease  all parts  and examine for  wear 
14.  Renew  the  bearings (if worn),  oil seals  and  joint 
15. 
If the  bearing in the top  cover  is worn  renew  the 
Assembling 
Cleanliness,  during  the following  instructions,  is 
essential. 
16. Press  or drift  in the  worm,  shaft-end, bcaring track 
ensuring  that the  same  shim 
or one of the  same 
value 
is fitted  behind  the  track. It is essential  that 
the  track  is fitted squarely and  pressed fully home. 
17.  Lubricate  and 
fit the bearing  to the  shaft  and insert 
the  shaft into the  box. 
18. Lubricate and fit the opposite  bearing and track  to 
the  worm. 
19. Fit the  cover  plate, joint  washer and original  shims. 
Secure  with the four  bolts  and evenly  tighten  to 25 
to 30 Nm (18 to 22  Ibs  ft). 
20.  Check  the worm  shaft  bearing  pre
-load by 
attaching  special tool 
R01016 or a  similar 
alternative 
63,5 mm (2.5  in) diameter, to the worm 
shaft.  Wrap string  round 
the tool and  attach  a 
spring  balance 
to one  end and with  a steady  pull 
note  the rolling  resistance  which should  be  2.26 
to 
2.72 Kg (5 to 6 Ibs force).  Adjust  by adding  or 
subtracting  shims.  When  the correct  figure 
is 
achieved,  remove the bolts,  coat the threads  with 
sealant  and 
fit and evenly  tighten  to  within the 
above  torque  figures. 
- 
and damage. 
washers and any  other unsatisfactory  parts. 
complete  cover with bearing. 
57 
ST 887M 
21. With  the lip side  leading fit the  oil  seal  to the 
shaft
-end  of the box. 
NOTE: 
When  performing  instructions 22, 23 and 26 
pressure must only be applied to the  hardened  square 
end 
of the  bearings. 
22.  Press  in the  sector  shaft top bearing to a  depth  of 
83 mm (3.150 in)  from the  top  machined  face of 
the steering  box. 
23.  Press  in 
the sector  shaft  lower bearing 1,OO mm 
(0.040 in)  below the chamfer. 
24.  Check  that 
no end-play  exists  in the sector  shaft 
adjuster. 
To reduce  end-play unstake  the threaded 
cup  and turn  clockwise  until all play 
is removed  and 
restake. 
25. Fit the sector shaft so that the roller is in the centre 
of the worm in the straight ahead  position. 
26. 
Fit the  bearing to the  sector  shaft top cover. 
27.  Screw  the top  cover  onto the adjuster  and secure 
with  the  four  bolts and evenly  tighten  to  25 
to 
30 Nm (18 to 22  Ibs  ft). 
28.  Loosely 
fit the adjuster  locknut. 
29.  Keeping  the  sector shaft 
in the straight  ahead 
position  fit the  drop  arm and  turn  the adjuster 
clockwise  until  pre
-load is applied  to the shaft. The 
amount  of pre-load  should  be such  that when  the 
shaft  is turned  half a turn  to the  left  then  half a turn 
to 
the right,  the backlash  must only  just  be 
perceptible.  When satisfactory  tighten the adjuster 
locknut. 
30. 
Fit the sector shaft oil seal. 
31.  Remove  the 
oil filter plug and  pour  in 
approximately 
0,43 litres  (0.75 pints) of the 
appropriate  recommended 
oil to  a minimum  level 
of  25 
mm (1.0 in)  below the top  of the  filler  hole. 
Refit  the plug  and tighten  to 
20 Nm (14.75 Ibs ft). 
1  
						

							157 I STEERING 
ST885M 
KEY TO MANUAL STEERING BOX 
17 
1. Adjuster lock nut. 
2. Top cover  retaining  bolts. 
3. Topcover. 
4. Top cover  joint washer. 
5. Sector  shaft. 
6. Worm shaft retaining plate and  bolts. 
7. Worm shaft shim(s). 
8. Worm shaft joint  washer. 
9. Worm  shaft. 
10. Worm shaft taper bearing. 
11. Worm  shaft oil seal. 
12. Worm shaft bearing track  shim. 
13. Sector shaft oil seal. 
14. Sector  shaft needle  roller bearings. 
15. Worm shaft grommet. 
16. Sector  shaft adjuster. 
17. Sector  shaft threaded  cup. 
18. Oil filler plug  and washer. 
2  
						

							STEERING I57 I 
r I . , ... REMOVE AND OVERHAUL  STEERING 8. Remove  the four screws  securing  the instrument 
panel  and pull  panel  away  from facia to enable  the 
COLUMN : I .,I, -_. .L * 
Remove the collapsible shaft speedometer  cable to be  disconnected. 
9. Also disconnect  two block conncctors. one 
1. Remove  the bonnet. 
2. Set  the  road  wheels  and  steering  wheel in the 
3. Mark  the relationship  of the  steering  column inner  multiplug 
connector  and one white  wire and 
withdraw  the panel  complete  with instruments. 
straight  ahead position. 
shaft 
to the top  universal  joint. 
4. 
NOTE: The Collapsible  shaft can be disconnected 
from  the steering  column only, if required,  by 
removing  the bolts  from  the top universal  joint and 
slackening  the top  bolt  of the  lower  universal  joint. 
Remove the  two bolts  from the  top universal  joint 
and 
the lower  bolt of the  bottom  universal  joint. 
Slacken  the top  bolt 
of the lower  universal  joint 
and  withdraw 
the shaft. 
Remove  the steering  wheel 
5. Remove  the  single  screw  retaining  steering wheel 
finisher and  remove the finisher. 
6. Remove the steering  wheel retaining nut and if 
necessary,  use a  suitable  puller to remove  the 
wheel. 
Remove  the instrument  panel 
7. Disconnect the battery. 
Remove the steering  column switches 
10. Remove  five screws  and two self-tapping  screws to 
remove the top half of the nacelle. 
11. Ease the bottom  half of the nacellc from the four 
switch  grommets  and disconnect  the mixture 
control cable  (Petrol vehicle)  and remove the 
lowcr 
nacelle. 
12. Disconnect  the four  multi-plugs,  one for each 
13. Remove  one clamp  screw on top of the  switch 
switch 
making  note 
of their positions. 
cluster  and withdraw 
the switches. 
continued 
3  
						

							STEERING 
Remove the steering  column lock-switch 
14. Note the position of the  wires  on the  back of the 
lock  switch  and disconnect  the lucars. 
15. Using  a  punch  or stud  extractor  remove the two 
shear  bolts securing  the switch  to the  column. 
Remove  the  switch and collect  the two  plain 
washers  between  the switch  and clamp. 
b 
ST572M 
Remove  the steering  column 
21. Remove  the bolt  securing  the tie-bar  to the  stecring 
column,  behind the instrument panel. 
Remove  the brake pedal box 
16. Remove  the  vent  cover  and the strip  retaining  the 
mill board trim covering  the brake  pedal 
mechanism  and remove  the  trim,  to  expose the 
pedal  box bolts. 
17. Remove the two  nuts  securing  the  brake  master 
cylinder 
to the servo and disconnect the vacuum 
hose  from  the servo. 
18. Remove  the six bolts  retaining  the pedal  box to the 
19. Disconnect  the wires  from the stop  lamp switch. 
20. Taking  care not to damage  the  brake  fluid pipes 
remove the pedal  box from the bulkhead  complete 
with  the brake  pedal assembly. 
bulk 
head. 
ST575M 
4 
22. Remove  the two  bolts  securing  the lower  end of the 
continued 
column.  
						

							STEERING ~ 
,: .I,_( . 23. 
Remove  the  two  bolts securing the two  halves  of 
the  top clamp  and the  two bolts  that secure the  top 
half  of the  clamp  to the  bulkhead  and  remove  the 
clamp  and rubber  packing. 
24. Remove  the  two bolts  securing  the column  inaia 
support  bracket 
to the bulkhead. 
25.  Remove 
the steering  column and main  support 
bracket from  the vehicle.  29. 
Drive  the needle  bearing  from the outer  column. 
C.  . *. I- 
ST576M t I 
Overhaul the steering  column 
26. Remove  the circlip  from the lower  end of the 
steering column. 
27. Drift out the inner  shaft  complete  with bearing 
from  the top  end 
of the column. 
28.  Remove  the  roll pin from  the  bearing  retaining 
collar  and  drive the collar  and bearing  from 
the 
inner shaft. 
ST577M 
shaft. 
31.  Fit  the  retaining  collar, ensuring  that 
it butts 
against  the bearing  and  that  the 
roll pin holes linc 
up. Secure  with the roll pin. 
32.  Fit a  new roller  bearing  to the  top end 
of the outer 
column 
to a  depth of 10 mm. 
33.  Fit  the inner  shaft and bearing  assembly  to the 
outer column and  secure with the circlip. 
continued 
ST579M 
5  
						

							Ei STEERING 
Fitting steering column 
34.  Fit the main  support  bracket  and  padding  to the 
steering  column and manoeuvre  the column  into 
position 
in the  vehicie. 
35.  Loosely  secure  the main  support  bracket and 
harness bracket to the  bulkhead  with two bolts. 
36.  Loosely 
fit the clamp and  rubber  packing strip to 
the column  and retain with two bolts. 
37.  Loosely  secure  the lower  end of the  column 
to the 
lower  support bracket  with two nuts and  bolts. 
38.  Loosely  secure the  clamp  bracket to the  main 
support  bracket with two bolts. 
-- 
41.  Fit the  pedal  box and secure  with the six bolts. Fit 
the  pedal  assembly  mill board  trim and secure  with 
retaining  strip, vent  cover and screws. 
42. 
Fit the  master  cylinder  to the servo and connect  the 
servo  vacuum  hose. 
43.  Connect the  stop lamp  switch 
leads. 
Fit steering  column lock switch 
44. Place  lock switch  in position  and rotate  the steering 
column  inner  shaft  to  line up the  slot  with the 
switch  plunger. 
continued 
39. 
Wn-bing inside  the vehicle  cab, fit the tie-bar to the 
cc 
40. Fir.. .ly tighten  the main  support  bracket  bolts, 
clamp  bracket  bolts,  upper clamp  bolts  and  the 
lower  support  bracket  nuts and bolts. 
n bracket and secure  with the single  bolt. 
6