Land Rover Defender 90 110 Workshop Book 4 Rover

							* .. . , .. .. . .. . 
STEERING 
I. . 
57 
... ? . . .. . ... .. 
45. Secure  the lock  to the  column  with the clamp  and 
shear  bolts,  whilst  inserting  two plain  washers 
between  the switch  and clamp.  Tighten  the bolts 
but  not enough 
to shear  them.  Temporarily  fit the 
steering  wheel 
and operate the switch  and lock 
mechanism  several times to ensure  it functions 
properly  before finally tightening  the bolts  until the 
heads shear.  Connect  the electrical leads to the 
rear 
of the  switch. 
ST583M 
Fit steering column switch assembly 
46.  Fit the  steering  column switch assembly  and secure 
with  the single  screw.  Connect  the four  multi
-plugs 
to  the  main  harness. 
Fit instrument panel  and nacelle 
47. Offer  up the  instrument  panel and connect  the 
speedometer  cable, two block  connectors  one 
multi
-plug  and single  white wire. Secure  the panel 
with  the four  screws. 
7 
48. Locate  the top  half of the  nacelle  in position  and fit 
the  mixture  control cable (Petrol  only) to the  lower 
half.  Locate  the switch  grommets  and 
securc the 
two  halves  together  with the four  long  screws 
one 
short  and two self-tapping  screws. 
Fit the steering wheel 
49. Turn the cancelling  ring so that the slots  are 
vertical  and the lug with  the arrow  points  to the 
left,  in the  direction 
of the  indicator  switch. Engage 
the  steering  lock. 
50.  Fit the  steering  wheel with the finisher  attachment 
lug  at the  bottom.  Ensure that the indicator 
cancelling  forks locate  in the  cancelling  ring slots. 
Secure  the wheel  with the shake
-proof  washer  and 
nut  and  tighten 
to the correct  torque.  Fit the 
finisher and secure  with the single  screw. 
continued 
7  
						

							STEERING 
ST587 M 
Fit collapsible  steering shaft  POWER 
STEERING 
BOX OVERHAUL - Adwest e 
early vehicles 
Service  tools: 
C Spanner - 606600 
Peg Spanner - 606601 
Ring  expander 
- 606602 
Ring  compressor 
- 606603 
Seal  saver,  sector shaft 
- 606604 
Seal  saver,  valve and worm 
- R01015 
Torque  setting tool - R01016 
DISMANTLE 
1. Remove  the  steering box from  the  vehicle,  and 
51. 
52. 
If necessary,  fit new universal  joints to the support. 
Note that the 
long joint is fitted  to the short  length 
of shaft and short joint to the long  end.  The joints 
can  only  be fitted  one way  to the  shaft. 
With  the steering 
lock engagcd and the road  wheels 
in the straight  ahead position  line-up the  marks  withdraw 
the drop  arm. 
made 
in instruction 2 and fit the  collapsible  shaft  
assembly with the long  leg  of the  shaft  to  the 
steering  box. Fit 
the pinch  bolts  and tighten  to the 
correct  torque figure. 
ST 104 3 M 
2. Rotate  the  retainer  ring, as necessary, until one 
end  is approximately  12 
mm (0.500 in) from  the 
extractor  hole. 
3. Lift the cover retaining ring from  the groove  in the 
cylinder  bore, using a suitable  pointed drift applied 
through the hole provided  in the  cylinder  wall. 
4. Complete the  removal of the retainer  ring, using a 
screwdriver. 
5. Turn on left lock (L.H. steering)  until the piston 
pushes  out the end  cover  (for 
R.H. steering 
models,  turn 
on right lock). 
ST588M 
continued 
8  
						

							STEERING 
15. Tap the splined end of the spindle shaft  to free  the 
bearing. 
3 
57 
16.  Withdraw  the bearing  cup and caged  ball bearing 
17.  Withdraw  the valve  and worm assembly. 
18. 
Do not  disturb  the  trim  screw,  otherwise the 
calibration  will be adversely  affected. 
19. Withdraw  the inner  bearing  ball race  and shims. 
Retain  the shims. 
6. 
Slacken  the  grub screw  retaining  the rack  pad 
7. Remove  the rack  pad adjuster. 
8. Remove  the sector shaft  adjuster locknut. 9. Remove the sector shaft  cover fixings.  assembly. 
adjuster. 
10. Screw  in the  sector shaft adjuster  until the cover  is 
removed. 
11.  Slide  out the sector shaft. 
ST 10 4 5 M 
l6 R 17 
Steering box seals 
20. Remove  the circlip  and seals from  the scctor shaft 
housing  bore. 
NOTE:  Do not remove  the  sector  bush  unless 
replacement 
is required.  Refer to instruction 23. 
21. Remove  the circlip  and seals  from the input  shaft 
housing  bore. 
NOTE: Do not remove  the  input  shaft  needle 
bearing unless replacement 
is required. 
12. Withdraw  the  piston, using a  suitable UNC bolt 
13. Remove  the  worm  adjusting  screw locknut  using 
14. Remove  the worm  adjusting  screw  using  peg 
screwed 
into 
the tapped hole in the  piston. 
‘C’ spanner 606600. 
spanner 606601. continued 
.! .’ 
9  
						

							STEERING 
26 
ST1050M 
Sector shaft assembly 
27. Check that  there is no side play on the rollers. 
28.  If excessive  side play 
on the roller  does exist renew 
29. Check the  condition of the adjuster  screw threads. 
30.  Examine  the  bearing areas on the  shaft  for 
31. 
Examinc the  gear  teeth  for uneven or  excessive 
the 
sector shaft. 
excessive  wear. 
wear: 
Inspecting 
22. Discard all rubber seals  and provide  replacements. 
NOTE: A rubber seal is fitted behind  the plastic 
ring 
on the  rack  piston.  Discard  the seal  also  the 
plastic  ring and provide  replacements. 
22 
ST1049M 
STlOSl M  32 
Sector shaft cover  assembly 
32. The  cover,  bush and seat  are supplied  as a 
Steering  box casing 
23. If necessary,  replace  the  sector  shaft bush,  using c=mp!ete assemb!j! fe: :ep!ace!??en? pllrpnses. suitable  tubing as  a drift. 
wear.  replacement  is necessary  this can  be undertaken  by 
using  a suitable  tap. 
24. 
Examine  the piston  bore for traces  of scoring  and 
25. Examine  the inlet  tube  seat  for damage. If 33. The  locknut  functions also  as a fluid seal  and must 
sector shaft adjuster locknut 
e-.. be replaced  at overhaul. %:.:/ 
26. Examine  the feed  tube for signs  of cracking. 
10 
continued  
						

							STEERING 
::: ., ., 
.. . ,, .-. . .. .. . ... .- . __ . ... 
Valve and worm  assembly 
34. Examine  the valve  rings  which  must be free  from 
cuts, scratches  and grooves.  The valve rings  should 
be  a loose 
fit in the  valve  grooves. 
35. Remove  the  damaged  rings ensuring  that no 
damage 
is done  to the  seal grooves. 
36.  If required, 
fit replacement  rings, using the ring 
expander  606602. Both rings and  tool  may be 
warmed 
if found  necessary.  Use  hot  water  for this 
purpose.  Then insert  into  the  ring compressor 
606603  to cool. 
NOTE: Any  sign of wear  at locations 39,40 and 41 
make  it essential  that the complete  valve and worm 
assembly  are renewed. 
Ball  bearing  and cage 
assem blies 
42. Examine  the  ball races  and  cups  for wear  and 
43.  If the  ball  cage  has worn  against the bearing cup, 
fit 
44. Bearing  balls must  be retained  by the  cage. 
45.  Bearings  and cage  repair  are carried  out by the 
complete.  replacement  of the  bearings  and cage 
assembly.  The bearing  cup  may be replaced 
separately 
only. 
46. To remove the inner  bearing  cup and shim 
washers,  jar the steering  box on the work  bench. 
general condition. 
replacements. 
NOTE: The 
expander  will not pass  over  rings 
already  fitted. These rings must be discarded 
to 
allow  access  then renewed. 
NOTE: Should  difficulty  be experienced  at this 
stage,  warm the casing  and the bearing  assembly. 
Cool the bearing  cup using  a suitable  mandrel  and 
jar  the steering  box on the  bench. 
ST1052M 
37.  Examine the bearing  areas for  wear.  The areas 
must  be smooth and 
not indented. 
38.  Examine  the  worm track 
which  must be  smooth 
and  not indented. 
39. Check  for  excessive end-float between  the worm 
and  valve  sleeve.  End
-float must  not exceed 
0,12 mm (0.005 in). 
40.  Rotary  movement  between  the components at the 
trim  pin 
is permissible. 
41. Check  for  wear  on the  torsion  bar assembly  pins; 
no free  movement  should  exist between  the input 
shaft  and the worm. 
JI ST10 5 3 M 
45 
Rack  thrust  pad and  adjuster 
47. Examine the  thrust pad for scores. 
48.  Examine  the adjuster  for wear 
in the  pad  seat. 
49.  Examine  the nylon  pad and  adjuster  grub screw 
assembly for  wear. 
49 I 
continued 
40 
 
47 
  
						

							1571 STEERING 
Rack and piston 
50. Examine for  excessive wear on the rack  teeth. 
51. Ensure  the thrust  pad bearing  surface is free  of 
scores and  wear. 
52. Ensure that the piston outer diameters  are free 
from  burrs  and damage. 
53. Examine  the  seal and ring  groove  for scores  and 
damage. 
54. Fit a new  rubber  ring to the  piston. Warm  the white 
nylon seal  and fit this to  the piston.  Slide  the piston 
assembly  into the cylinder  with the rack  tube 
outwards.  Allow to cool. 
REASSEMBLE 
52 
NOTE: When  fitting  replacement  oil seals,  these  must 
be lubricated with  recommended fluid.  Also ensure  that 
absolute  cleanliness 
is observed during  assembly. 
Input shaft  oil seal 
56. Fit  the  seal,  lipped  side  first,  into the housing. 
When  correctly  seated, the  seal backing  will 
lie flat 
on  the  bore shoulder. 
57. Fit the extrusion washer  and secure  with the circlip. 
ST 10 58 M /I 
ST1056M 
Input  shaft needle bearing 
55. If necessary, replace  the bearing.  The replacement 
must  be fitted squarely 
in the  bore (numbered  face 
of the bearing  uppermost).  Then, carefully  push 
the  bearing  in until  it  is flush  with the  top 
of the 
housing  bore, Ideally,  the bearing  will be just  clear 
of the bottom  of the  housing  bore. 
Sector shaft seal 
58. Fit the  oil seal, lipped  side first. 
59. Fit the  extrusion washer. 
60. Fit the dirt  seal, lipped  side last. 
61. Fit the  circlip. 
continued 
55 / 
12  
						

							STEERING 
Fitting the valve and worm assembly 
62. If removed,  refit the original  shim washer(s) and 
the inner  bearing  cap.  Only  vaseline  must be used 
as an  aid to assembling  the bearings. 
NOTE: If the  original shims are not available,  fit 
shim(s) of 0.76 mm (0.030 in) nominal thickness. 
63. Fit the inner  cage and bearings assembly. 
64.  Fit  the valve  and worm  assembly,  using  seal  saver 
R01015 to protect the input shaft seal. 
65. 
Fit the outer  cage and bearings  assembly. 
66. 
Fit the outer  bearing cup. 
SrlOSl M 
Fitting the  rack and piston 
71. Screw a  suitable  bolt into  the piston  head for use  as 
an assembly  tool. 
72.  Fit  the piston  and 
rack assembly so that the piston 
is  63.5 
mm (2.5  in) approximately  from the outer 
end 
of the  bore. 
73.  Feed  in the  sector  shaft using  seal saver  606604 
aligning 
the centre gear  pitch on the  rack  with the 
centre  gear tooth  on 
the sector  shaft.  Push in the 
sector shaft, and, at the  same  time rotate  the input 
shaft  about  a  small  arc to  allow  the sector  roller 
to 
engage the worm. 
continued 
67. Renew the  worm adjuster  sealing  ring  and loosely 
screw  the adjuster into the  casing. 
Fit the locknut, 
but  do not  tighten. 
68.  Turn  in the  worm  adjuster  until the end
-float  at the 
input  is almost  eliminated. 
69.  Measure  and  record the maximum  rolling distance 
of the valve  and  worm  assembly, using a spring 
balance  and cord  coiled  around the torque  setting 
tool 
R01016. 
70. I----- IUIII III .- the worm adjuster to increase  the figure 
recorded  in instruction  69 by 
1,8 to 2,2 kg (4 to 
5 Ib)  at 1.250  in (31.7 mm) radius  to settle the 
bearings, then  back 
off the worm  adjuster  until the 
figure  recorded  in instruction 69  is increased  by 
0,9 
to 1,3 kg (2 to 3 Ib)  only,  with the locknut  tight. 
Use  peg spanner  606601 and 
C spanner  606600. 
13  
						

							STEERING 
Fitting the rack  adjuster 
74. Fit the sealing ring  to the rack adjuster. 
75.  Fit the  rack  adjuster  and  thrust  pad 
to engage the 
76. Loosely fit the nylon  pad and  adjuster  grub screw 
Fitting  the cylinder  cover 
82. Fit the  square section seal  to the cover. 
83.  Remove  the slave  bolt and press  the cover  into the 
cylinder  just  sufficient to clear  the retainer  ring 
groove. 
84.  Fit  the  retainer  ring to the  groove  with one end 
of 
the ring  positioned  12 mm (0.5 in)  approximately 
from  the extractor  hole. 
rack. 
Back off a half  turn 
on the adjuster. 
assembly  to engage the  rack adjuster. 
76 75 
ST1063M 
Fitting  the sector  shaft cover 
77. Fit the  sealing ring to the cover. 
78.  Screw  the cover  assembly  fully on to the  sector 
79.  Position 
the cover on to the  casing. 
80.  Tap  home  the cover.  If necessary  back off 
on the 
sector  shaft  adjuster screw  to  allow the cover  to 
joint  fully with  the casing. 
shaft 
adjuster  screw. 
NOTE: 
Before  tightening  the fixings,  rotate the 
input  shaft about 
a small  arc to ensure  that the 
sector  roller 
is free to move in the  valve  worm. 
81. Fit the cover  fixings  and  torque  load to 2,2  to 2,8 
kgf 
m (16 to 20 Ibf  ft) (23  to 28 Nm). 
Adjusting  the sector  shaft 
85. Set the worm on centre  by rotating  the  input  shaft 
half  the total  number  of turns  from either  lock. 
86. Rotate  the sector  shaft  adjusting  screw anti- 
clockwise  to obtain  backlash  between the input 
shaft and the  sector shaft. 
87.  Rotate  the sector  shaft  adjusting  screw clockwise 
until  the backlash 
is just  eliminated. 
88.  Measure  and  record  the maximum  rolling 
resistance  at the  input  shaft, 
using a spring balance, 
cord and torque  tool 
R01016. 
89.  Hold still the  sector  shaft  adjuster  screw and 
loosely  fit a new  locknut. 
90. Turn in the  sector  shaft  adjuster  screw until the 
figure 
recordcd in instruction 88 is  increased  by 0,9 
to 1,3 kg (2 to 3 Ib) with the locknut  tightened. 
f. t. d 
continued 
ST1064M 
14  
						

							STEERING El 
e,t:i:t Adjusting the rack  adjuster 
91. Turn in the rack  adjuster  to increase  the figure 
recorded 
in 90 by 0,9 to 1,3 kg (2 to 3 lb).  The  final 
figure  may be less  than  but must  not exceed 
7,25 kg 
(16 Ib). 
92. 
Lock the  rack  adjuster  in position  with  the  grub 
screw.  Adjustments 
95. Note 
where  the  greatest  figures are recorded 
relative  to the  steering  gear position.  If the  greatest 
figures  are not recorded  across the centre 
of travel 
(i.e.  steering  straight ahead position),  adjust  as 
follows: 
L.H.  steering  models. If  the torque  peak occurs 
before  the centre  position,  add  to the  shim 
washer valve;  if the  torque  peak occurs  after 
the  centre  position,  subtract from 
the shim 
washer  valve. 
R.H.  steering  models. 
If the torque  peak  occurs 
before  the centre  position,  subtract  from  the 
shim  washer  valve; 
if the torque  occurs after 
the  centre  position,  add to the  shim  washer 
valve. 
Shim washers  are available  as follows: 
0,03 mm, 0,07 mm, 0,12 mm and 0,24 mm (0.0015 in, 
0.003 in, 0.005 in and 0.010 in). 
Torque 
peak check 
With  the input  shaft  rotated from lock
-to-lock,  the 
rolling  resistance  torque figures should  be greatest 
across  the centre  position 
(1% turns  approximately 
from  full lock)  and equally  disposed  about  the  centre 
position. 
This  condition  depends on the value 
of shimming  fitted 
between 
the valve  and worm  assembly  inner bearing 
cup  and the  casing. 
The original  shim washer  value will 
give  the correct  torque  peak  position unless major 
components have been replaced. 
NOTE:  During the following  Procedure,  the stated 
positioning  and direction 
of the input  shaft applies for 
both L.H. and R.H. boxes.  However,  the procedure  for 
shim  adjustment  where necessary,  differs between 
L.H. 
and R.H. steering  boxes and is described  under the 
applicable  L.H. stg. and  R.H.  stg. headings. 
- 
Procedure 
93.  With 
the input  coupling  shaft  toward the operator, 
turn 
the shaft  fully anti-clockwise. 
94.  Check  the torque  figures  obtained  from lock
-to- 
lock  using  a  spring balance  cord  and  torque tool 
R01016. 
NOTE: Adjustment of 0,07 mm (0.003 in) to the  shim 
value 
will move  the torque  peak area .by 9 turn 
approximately  on the  shaft. 
96.  Fit the  drop  arm to the  steering  box 
using a new tab 
washer.  Tighten  the nut  to  the  correct  torque and 
bend  over tab. 
97. Refit  the steering  box to the  vehicle. 
98. Replenish  the system  with  the  correct grade of 
fluid.  Refer  to  Recommended  Lubricants  and 
bleed  the system. 
99. Test  the system  for leaks,  with the engine running, 
by  holding  the steering  hard  on full  lock  in both 
directions. 
NOTE: 
Do not  maintain  this pressure  for more  than 
30 seconds  in any  one minute  to avoid  over-heating 
the  fluid 
and possibly  damaging  the seals. 
100. Road  test the vehicle. 
..  
						

							171 STEERING 
BLEEDING THE POWER  STEERING  SYSTEM 
TEST POWER  STEERING  SYSTEM 
Service  tools: 
Three
-way  adaptor - JD10-2/1 
Gauge - JDlO 
Hose - JD 10-3 
2-off Hose - JDIO-3A 
Adaptor 
- JD10-6/1 
Adaptor - JD10-6/2 
If  there  is a lack  of power assistance  for the steering  the 
pressure  of the  hydraulic  pump should  be checked  first 
before  renewing  any components 
of the  system.  The 
fault  diagnosis  chart  should  also  be used to assist  in 
tracing faults  in the  power  steering. 
PROCEDURE 
1. The hydraulic  pressure  test  gauge is used in 
conjunction  with the special  adaptor (as  illustrated) 
for  testing  the power  steering  system. This  gauge is 
calibrated  to read  up 
to 140 kgf/cm’ (2000 Ibf/in2) 
in the  power  steering  system is 60 kgf/cm2 
(850 Ibf/in2j. 
2. Under certain  fault  conditions of the hydraulic 
pump  it is  possible  to obtain  pressures  up 
to 
105 kgf/cm2 (1500 lbf/in2). Therefore,  it is 
important  to realise  that  the  pressure upon the 
gauge  is in  direct  proportion 
to the pressure  being 
exerted  upon  the  steering wheel.  When  testing, 
apply  pressure  to 
the steering wheel very gradually 
while  carefully  observing  the pressure gauge. 
3. Check,  and if necessary  replenish,  the  fluid 
reservoir. 
4. Examine  the power  steering  units and connections 
for  leaks.  All leaks  must  be rectified  before 
attempting  to test  the system. 
5. Check the steering  pump drive belt for condition 
and tension,  rectify as neccssary. 
The  pump  used 
on the V8 engined  vehicle is 
different  from  that fitted  to the  four  cylinder T-r 
engined vehicles  but the test  figures  are the  same 
for  both  pumps,  Diagrams  show  how 
the test 
equipment  is assembled  for both  vehicles. 
6. Assemble  the test  equipment  in accordance  with 
the  diagram  for the vehicle  concerned. 
7. Open the tap  in the  adaptor JD10-211. 
8. Bleed  the system  but  exercise  extreme  care  when 
carrying  out this  operation 
so as not to overload  the 
pressure gauge. 
9. With  the system  in good  condition,  the pressures 
should  be as 
follows: 
(a)  Steering  wheel held  hard on full lock  and 
engine  running  at 
1,000 rev/min, the pressure 
shouici be 60 to 67 i