Land Rover Defender 90 110 Workshop Book 4 Rover

							STEERING 
These checks  should  be carried  out first  on one  lock, 
then  on the  other. 
57 
CAUTION: Under  no circumstances  must  the  steering 
wheel  be  held on full  lock  for  more than 
30 seconds  in 
any  one  minute,  otherwise  there will  be  a  tendency 
For 
the oil to overheat  and possible damage  to the  seals  may 
result. 
LU 
ST915M 
110 and 90 Engine Diagram 
A Steering  box. 
B Steering  pump. 
C Existing hose, steering  box to pump. 
D Hose JD10-3A. 
E Test adaptor JD10-2. 
F Pressure  gauge HY23. 
G Hose JDIO-3A. 
H Thread adaptor JDlO-6. 
I Thread  adaptor JDlO-6. 
ST916M 
V8 Engine Diagram 
A Steering  box. 
B Steering pump. 
C Existing hose, steering  box to pump. 
D Hose JD10-3. 
E Test  adaptor JD10-2. 
F Pressure  gauge HY23. 
10. Release the steering  wheel  and  allow the engine  to 
idle.  The pressure  should be: 
7 kgfkm’ 
(100 Ibf/in2). 
11. If the  pressures  recorded during the foregoing  test 
are  outside  the specified 
rangc, or pressure 
imbalance 
is recorded,  a fault  exists in the system. 
To determine if the  fault  is in the steering  box or 
the pump,  close the adaptor  tap for a period not 
exceeding  five seconds. 
12. If the  gauge  fails to register  the specified  pressures, 
the  pump  is inefficient  and the pump  relief valve 
should  be examined  and renewed  as necessary. 
13.  Repeat  the foregoing  test after  renewing  the relief 
valve  and bleeding  the system.  If the  pump 
still 
fails  to achieve  the specified  pressures,  the pump 
should  be overhauled  or 
a new unit fitted. 
14. If pump  delivery is satisfactory  and low pressure  or 
marked  imbalance  exists, the fault  must  be 
in the 
steering  box valve  and worm  assembly. 
17  
						

							57 
AD JUST POWER STEERING BOX 
STEERING 
NOTE:  The condition of adjustment  which must be 
checked is one of minimum  backlash without 
overtightness  when the wheels  are in the  straight
-ahead 
position. 
1. Jack  up the front  of the  vehicle  until the wheels  are 
clear 
of the  ground. 
WARNING:  Wheels must be chocked  in all 
circumstances. 
2. Gently rock  the  steering  wheel about the  straight- 
ahead  position  to obtain  the ‘feel’ of the backlash 
present.  This  backlash must  not  be more  than 
9,5 mm (0.375  in). 
3. Continue  the  rocking  action  whilst an  assistant 
slowly  tightens  the steering  box adjuster  screw after 
slackening 
the locknut  until the rim  movement  is 
reduced  to 
9,5 mm (0.375 in) maximum. 
4. Tighten  the locknut,  then  turn  the  steering  wheel 
from  lock to lock  and check  that 
no excessive 
tightness  exists at any  point. 
5. Lower  the vehicle  to ground  level and  remove  the 
6. Road test the vehicle. 
wheel 
chocks. 
V8 ENGINE POWER STEERING PUMP 
OVERHAUL - Series 30 
Dismantle 
1. Remove the  steering pump from the vehicle. 
2. Clean  the exterior of the pump  and  drain off any 
oil. 
3. Remove the bolt,  spring  washer  and large  plain 
washer securing  the pulley  to the pump shaft. 
4. Using  a  suitable  puller, withdraw  the pulley. Do 
not  attempt  to hammer  the  shaft from the pulley, 
or  lever  the pulley  from the shaft, as  this may  cause 
internal  damage. 
5. Withdraw  the square  key from  the shaft. 
6. Remove the four  bolts and spring  washers  securing 
the  bearing  retainer plate  and front mounting plate 
to  the  pump  body. Remove the  plates. 
7.  Remove  the three  bolts and spring  washers 
securing  the rear  mounting  plate to the  pump body 
and  remove  the plate. 
8. Clamp the  pump body in a vice,  ensuring  that  the 
jaws  are protected. 
9. Remove  the union  bolt and withdraw  the fibre 
washer, inlet  adaptor and rubber  gasket. 
NOTE: The tubular  steel venturi flow director  under the 
inlet  adaptor 
is pressed  into the cover  and should  not be 
removed. 
10. Remove  the six Allen  screws securing  the cover to 
the  pump  body.  Separate  the cover  from the body 
vertically 
to prevent  the parts  falling  out. 
11. Remove  the pump from  the vice. 
continued 
18  
						

							STEERING 15711 
.. 12. Remove the ‘0’ ring  seals  from the grooves  in the 
13. Carefully  tilt the  pump  body,  and  remove  the six 
14.  Draw  the carrier  off 
the shaft, and remove  the drive 
15. Remove  the shaft  from the body. 
“ .- *I. 1 pump body. 
rollers. 
pin. c ”- 
5,42 
. ,., . . .. . .... 
15,28 
13fl 12,33 
// 
RR186M 14,30 
16. Remove  the cam  and the cam  lock  peg from  the 
pump  body. 
17.  If necessary  withdraw the sealed  bearing  from the 
shaft 
18. Remove the  shaft seal from  the body, ensuring that 
no damage is caused to the  shaft  bushing. 
19. Remove  the  valve cap, ‘0’ ring, valve  and valve 
spring  from the body.  Place all parts where 
they will 
not be damaged, or subject  to contamination. 
RR 187M 
NOTE: Ensure  that the aluminium  restrictor in the  output 
port is thoroughly  cleaned but not dislodged. 
Reassemble 
23. Carefully  examine a new  shaft  seal to ensure  that it is 
clean  and  undamaged.  Smear 
the sealing lips with 
grease and  apply a fine  smear  of ‘Wellseal’  to  the 
pump  body where 
the outside diamcter of the  oil seal 
locates  (applies  to metal cased seals).  Place the seal 
square  to the housing recess  with the lip towards the 
inside  of the  housing. 
24.  Press  the seal  into  position  approximately 
0.80 mm 
(& in) below the seal  housing face,  ensuring  that it 
does not tilt. 
25. Replace  the cam  lock  peg into the  location in the 
body. 
26. Renew the cam if worn  or damaged.  Refit the cam, 
ensuring that 
it seats  correctly in the body  and that 
the  slot  locates  over the locking  peg. 
27. Fit a new  sealed  bearing  onto the pump shaft. 
28. Insert  the shaft  and bearing  assembly  into the seal 
29. Refit the carrier  drive pin in the  shaft. 
30. Inspect the  carrier and replace in position,  ensuring 
that  the greater angle  on 
the carrier teeth is in the 
leading  position  as illustrated. 
side 
of the 
body. 
Y 
3 
RR183M 
Inspection 
20. Wash  all parts in a suitable solvent, air  dry, or wipe 
clean  with a lint
-free cloth if air  is not  available. 
21.  Check  the pump  body and cover  for wear.  Renew 
either  part, 
if faces or bushes  are worn. 
22.  Check 
the pump  shaft  around  the  drive  pin slot. 
Remove  any burrs. 
rollers. 
31. Inspect  the rollers,  paying particular attention to the 
finish  on  the  end. Renew  the rollers 
if scored, 
damage 
or oval.  Refit the  rollers to the carrier. 
32. Using  a straight  edge across  the cam  surface, and  a 
feeler  gauge,  check the end  clearance  of the  carrier 
and  rollers 
in the pump  body. If the end  clearance  is 
more  than 
0,05 mm (0.002 in) rencw the carrier  and 
19  
						

							STEERING 
32 
\\- 
6 a$ 
POWER STEERING BOX OVERHAUL - Lightweight 
Adwest 
Service  tools: 
‘C’ Spanner - LST120 
Worm adjusting  socket - LST119 
Drop arm extractor - MS252A 
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 arm from  the vehicle,  and 
withdraw  the drop arm. 
33.  Smear  a fine trace 
of Loctite  275 to the  pump  body in 
a ‘figure 
of 8’  outside the ‘0’ rings  and inside  the bolt 
holes.  Install new 
‘0’ rings to the  body  of the  pump. 
34.  Refit the  cover 
on the pump  body and secure  with six 
Allen  screws  and spring washers. 
35.  Tighten  the Allen  screws, 
in diagonal  sequence, 
checking  that the shaft  rotates  freely and does  not 
bind.  Final  torque 
to be 15 to 17 Ibf.ft (20 to 23  Nm). 
36.  Replace  the square  sectioned  rubber gasket 
to the 
groove  around  the inlet  port  and  replace the inlet 
adaptor,  fibre washer and  union bolt. Torque 
to 28 to 
30 
1bf.ft (38 to  41 Nm). 
secure  with three  bolts and spring  washers. 
retainer  plate 
to the pump  body and secure  with four 
bolts  and spring  washers. 
39.  Refit  the flow  control  valve spring  in the  bore.  The 
spring  tension  should be 
8 to 9 Ibf (11 to 12 Nm) at 
21 
mm (0.820  in). If not,  renew  the spring. 
40.  Replace  the valve  in the  bore,  inserting  the valve 
so 
37.  Refit  the rear mounting  plate to the pump  body and 
38.  Refit  the front  mounting  plate  and  the bearing 
RR923M 
43. 
44. 
f?“ tha; the exposed  ball end enters  last. Ensure that the 
valve is not  sticking. 
41.  Renew  the 
‘0’ ring on the valve cap and assemble  in 
the  pump.  Tighten  the cap to a torque  figure 
of 30 to 
35 
Ib.ft (40 to 47 Nm). 
2.  Rotate the  retainer ring, as  necessary, until one end 
is  approximately 
12 mm (0.500 in) from the extractor .er 
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. 
screwdriver. 
42. 
Refit  the pulley  key. ’ Refit the pulley to the shaft and with the 4. Complete the removal of the retainer ring, using a special  washer,  spring and  washer and bolt. Tighten 
the  bolt  to  a  torque figure 
of 10 to 12 Ibf.ft (13  to 5. Turn  on  left lock (LH steering)  until the piston ,L ’*TA_ 10 iumi. 
Refit  the steering  pump to the  vehicle.  pushes 
out the end  cover (for RH steering models, 
turn  on right 
lock). 
continued 
20  
						

							STEERING 
1 . ’. 
57 
5-K lll  
. RR1695M w 
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. 
adjuster. 
10. Screw 
in the sector  shaft adjuster  until the cover  is 
11.  Slide  out the sector  shaft. 
removed. 
1 
RR924M 
15. Tap 
the splined  end of the  spindle  shaft to free  the 
16.  Withdraw  the bearing  cup and 
cagcd ball  bearing 
bearing. 
assembly. 
l6 17  A 
17. Withdraw  the valve  and worm  assembly. 
18. Withdraw  the inner  bearing  ball race  and shims. 
Retain  the shims. 
continued 
12.  Withdraw  the  piston, using a suitable bolt  screwed 
13. Remove the worm  adjuster  locknut using ‘C’ 
14. Remove the worm  adjuster using socket LSTl19. 
into the tapped  hole in the  piston. 
spanner, 
LST120. 
‘I . 
. ; , 
21  
						

							157 I STEERING 
Steering box seals 
19. Remove  the circlip  and seals  from the sector  shaft Steering 
box casing 
22.  If necessary,  replace  the sector  shaft bush,  using 
23.  Examine  the piston  bore for traces 
of scoring  and 
housing 
bore. 
NOTE: Do not remove  the sector  bush unless  wear. 
replacement  is required.  Refer to instruction 
22. 
suitable  tubing as a drift. 
20. Remove the circlip  and  seals  from the input  shaft 
housing  bore. 
RR929M v/ 22 23 
24. Examine  the  inlet  tube seat for  damage.  If 
replacement  is necessary  this can be undertaken  by 
using  a suitable  tap. 
25. Examine the feed tube for signs of cracking. 
NOTE: Do not remove  the input  shaft needle 
bearing  unless replacement 
is required. Sectorshaftassembly 
26. Check  that there  is no  side play on  the rollers. 
27. If excessive  side play on the roller  does exist renew 
28. Check  the condition of the  adjuster  screw threads. 
29. Examine  the  bearing areas on the  shaft for 
30. Examine the gear teeth for uneven or excessive 
Inspecting 
21. Discard 
all rubber  seals and provide  replacements.  the 
sector  shaft. 
excessive  wear. 
wear. 
NOTE: A rubber  seal is fitted behind  the plastic 
ring  on the  rack 
Piston- Discard the sea1 also the 
plastic  ring and provide  replacements. 
RR928M 
22 
RR930M ‘3 2  
						

							STEERING 
/- .: ,,;...-, .: . .. _.. Sector shaft cover assembly ,..& . ..__., ....,_ . ,..,. =: ... i..Y., ..? 
31. The cover,  bush and seat  are supplied  as a U.. 
complete  assembly for replacement purposes. 
L 
57 
Sector shaft adjuster  locknut 
32. The locknut  functions also  as a fluid seal  and must 
be  replaced  at  overhaul. 
Valve  and worm assembly 
33.  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. 
*- .. . .. . .. . .. I. 
RR931M 
34. Remove  the damaged  rings ensuring  that no 
damage  is done  to the  seal  grooves. 
35. 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: The  expander  will not  pass  over  rings 
already  fitted. These  rings must be  discarded  to 
allow access  then renewed. 
36. Examine the bearing  areas for wear. The areas 
must  be smooth  and not indented.  37.  Examine 
the worm  track which  must be smooth 
and  not indented. 
38. Check for wear  on the  torsion  bar assembly  pins; 
no  free  movement  should 
cxist between the input 
shaft and  the worm. 
NOTE: Any sign of wear  makes  it essential  that the 
complete  valve and worm  assembly 
is renewed. 
Ball bearing  and cage assemblies 
39. Examine  the ball  races  and  cups  for  wear  and 
40.  If the  ball  cage  has worn  against the bearing  cup, 
fit 
general condition. 
replacements. 
41.  Bearing  balls must  be 
retained by the cage. 
42. Bearings  and  cage repair  are  carried out by the 
complete  replacement 
of the bearings  and cage 
assembly. 
43. To remove  the inner  bearing  cup  and  shim 
washers,  jar the steering  box 
on the work  bench, or 
use a suitable  extractor. 
NOTE: Should dificulty 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. 
continued 
36 
23  
						

							571 STEERING 
Rack thrust  pad and adjuster 
44. Examine the thrust pad for  scores. 
45.  Examine the  adjuster for wear  in the  pad  seat. 
46. Examine the nylon  pad for distortion and  adjuster 
grub  screw  assembly  for wear. 
46 
I 
I 
45 
I 
I 
44 
 
A 
1 W RR934M 
Rack and piston 
47. Examine for excessive  wear on the rack  teeth. 
48.  Ensure  the thrust  pad  bearing  surface is free  of 
scores and  wear. 
R 
Input shaft needle bearing 
52. 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. 
RR936M 
Reassemble 
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 
53. Fit  the  seal,  lipped  side first,  into  the housing. 
When  correctly  seated, the seal  backing  will lie flat 
on the bore  shoulder. 
54. Fit the extrusion  washer and secure  with the circlip. 
RR935M 
49. Ensure  that the piston  outer diameters  are free 
from  burrs and  damage. 
50. Examine  the  seal and ring  groove  for  scores  and 
damage. 
51. 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. 
24  
						

							STEERING 
Sector shaft seal 
57 
55. Fit the oil seal,  lipped  side first. 
56. 
Fit the extrustion  washer. 
57. 
Fit the  dirt  seal,  lipped  side last. 
58. Fit the circlip. 
Fitting the valve and worm assembly 
59. 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. 
, ...__ :>., .. ,.. 
						

							571 STEERING 
Fitting the rack  and piston 
68. Screw  a suitable  bolt into the piston  head for  use as 
an  assembly  tool. 
6 
. 
RR941M I J 
69. 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. 
70. 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. 
Fitting  the rack  adjuster 
71. Fit the sealing ring  to the  rack  adjuster. 
72.  Fit the  rack  adjuster and  thrust pad to engage  the 
rack.  Back off a half 
nylon turn on the adjuster. 
73.  Loosely 
fit the nylon pad  and adjuster grub  screw 
assembly  to engage  the rack  adjuster. 
Fitting  the sector  shaft cover 
74. Fit the  sealing ring to the cover. 
75.  Screw  the cover  assembly  fully 
on to the  sector 
shaft adjuster  screw. 
----- - 
76.  Position the cover on to the  casing. 
77. Tap  home  the cover. If necessary  back  off on the 
sector  shaft 
adjustcr screw to allow thc cover to 
joint  fully with the casing. 
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. 
78. Fit  the  cover fixings  and tighten  to the  correct 
torque. 
Fitting  the cylinder  cover 
79. Fit the square section  seal to thc cover. 
80. Remove the  slave bolt and  press the  cover into the “j-;. 
cylinder  just sufficient to clear  the  retainer ring 
groove. 
P: 
RR942M 
26