Land Rover Defender 90 110 Workshop Book 4 Rover

							STEERING 1571 
:-, ,. ,.Gz.::. ._,._ .* ,..z..y 
81. Fit the  retainer  ring to the groove  with one end of 
the  ring  positioned  12 
mm (0.5 in)  approximately 
from the extractor  hole. 
.. ./.>, . _. .... 
Adjusting  the sector  shaft 
82. Set the  worm on centre  by rotating  the input  shaft 
half  the total  number 
of turns from either  lock. 
RR945M 
83. Rotate  the sector  shaft  adjusting  screw  anti- 
clockwise  to  obtain backlash  between the input 
shaft  and the sector shaft. 
84.  Rotate  the  sector  shaft  adjusting screw clockwise 
until  the backlash  is just  eliminated. 
85.  Measure  and record  the  maximum  rolling 
resistance  at the  input shaft,  using a spring balance, 
cord  and torque 
tool R01016. 
86. Hold  still the  sector  shaft adjuster  screw  and 
loosely fit a new locknut. 
87.  Turn  in the  sector  shaft  adjuster  screw  until the 
figure  recorded 
in instruction 88 is increased  by 0,9 
to 1,3 kg (2 to 3 Ib) with the locknut tightened. 
Adjusting  the rack  adjuster 
88. Turn  in the  rack  adjuster to increase  the figure 
recorded  in 
90 by 0,9 to 1,3 kg (2 to 3 Ib). The  final 
figure 
may be  less  than  but must  not exceed 7,25 kg 
(16 Ib). 
89. Lock  the rack  adjuster in position  with the grub 
screw. 
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 Y2 turns approximately 
position. .. .. . .. . from full lock)  and equally  disposed  about the centre  The 
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 replace. 
NOTE: During the following  ‘Procedure’,  the stated 
positioning  and direction 
of the input  shaft applies  for 
both  LH and 
RH boxes.  However,  the procedures for 
shim  adjustment  where necessary,  differs between  LH 
and 
RH steering  boxes and is described  under the 
applicable  LH stg.  and 
RH stg. headings. 
Procedure 
90. With  the input  coupling shaft toward  the operator, 
turn  the shaft  fully anti
-clockwise. 
91. Check  the  torque  figures obtained  from lock-to- 
lock using  a  spring  balance  cord  and  torque tool 
R01016. 
w RR946M 
Adjustments 
92. Note  where  the  greatest  figures are recorded 
relative  to the  steering  position.  If the  greatest 
figures  are not recorded  across the centre of travel 
(i.e. steering  straight-ahead  position),  adjust  as 
follows: 
LH  steering  models. If the torque  peak occurs 
before the  centre  position,  add  to the  shim 
washer  value; 
if the torque  peak occurs after 
the  centre  position, subtract from the shim 
washer value. 
RH steering  models. If the  torque  peak  occurs 
before the centre  position,  subtract  from the 
shim  washer  value; 
if the torque  occurs after 
the  centre  position, add to the  shim  washer 
value. 
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). 
NOTE: Adjustment  of 0’07 mm (0.003 in) to the shim 
value  will move  the torque  peak area by 
‘/4 turn 
approximately  on the  shaft. 
27  
						

							57 
NOTE: Do not  maintain  this pressure for more  than 
30 seconds  in any  one minute to avoid  overheating 
the 
fluid and possibly damaging  the seals. 
STEERING 
97.  Road  test the vehicle. 
KEY TO ADWEST LIGHTWEIGHT POWER STEERING BOX 
1. Housing. 
2. Housing  bushes. 
3.  Seal. 
4.  Back
-up washer. 
5. Back-up seal. 
6.  Circlip. 
7. Seal. 
8. Drop-arm. 
9.  Tab  washer. 
10. Sector  shaft nut. 
11. Sector  shaft and follower  assembly. 
12.  Seal. 
13.  Bush. 
14.  Cover  plate. 
15.  Self  locking  screws
-4 off. 
16.  Bleed  screw. 
17.  Locknut. 
18. Rotor  seal. 
19.  Seal  washer. 
20. Circlip. 
21. Shims. 
22.  Bearing  track. 
23.  Bearing  case and balls.  24. 
Circlip. 
25.  Seal  torsion  bar. 
26.  Rotor. 
27.  Teflon  rings 
- 3 off. 
28. Stop-off  rings. 
29.  Worm. 
30. Bearing  cage and balls. 
31. Bearing  track. 
32.  Seal. 
33.  Worm  adjusting  screw. 
34. Locknut. 
35.  Piston. 
36. Piston ‘0’ ring. 
37.  Piston  Teflon  seal. 
38.  Cylinder  cover seal. 
39.  Cylinder  cover. 
40.  Cylinder  cover retainer. 
41.  Screw. 
42.  Rack  adjusting  screw. 
43.  Rack  adjusting  screw seal. 
44. 
Rackpad. 
45.  Fluid  line. 
28  
						

							.. .. . .. ... . .. . .I .. . .. 
I- 
T 
29  
						

							171 STEERING 
POWER STEERING  SYSTEM - Adwest Lightweight 
box 
Bleed 
1. Fill thc steering  fluid reservoir  to the  mark  on the 
side 
of the  reservoir  with  one of the recommended 
fluids. 
2. Start  and run the engine  until it attains  normal 
operating  temperature. 
3. Check and correct  the reservoir  fluid level. 
NOTE: During  the carrying  out of items 4, 5 and 6, 
ensure that the steering  reservoir is kept full. Do not 
increase  the engine  speed 
or move the steering  wheel. 
4. Run the engine  at  idle speed,  slacken  the bleed 
screw.  When  fluid seepage  past the bleed  screw  is 
observed,  retightcn the screw. 
ST1805M \\ --I/ v 
5. Ensure that  the  fluid level  is  in alignment  with the 
6. Wipe  off all fluid released during  bleeding. 
7. Check all hose  joints,  pump and steering box for 
fluid  leaks  under  pressure  by holding  the  steering 
hard  on 
full lock in both  directions. 
mark 
on 
thc reservoir dipstick. 
CAUTION: Do not maintain  this pressure for more 
than 
30 seconds  in any one minute, to avoid causing 
the oil to overheat  and possible  damage to the  seals. 
The  steering  should 
be smooth lock-to-lock in both 
directions,  that is, 
no heavy  or light  spots  when 
changing  direction when the vehicle 
is stationary. 
8. Carry  ut a short 
road test. If necessary,  repeat the 
30 
complete  foregoing  procedure. 
POWER STEERING SYSTEM - Adwest Lightweight 
box 
Test 
If  there  is a lack of powcr assistance  for the steering  the 
pressure  of the  hydraulic  pump should be checked  first 
before  rcncwing  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 uscd for testing 
the  power steering  system. This gauge 
is calibrated 
to  read  up  to 140 
kgf/cm2 (2000 Ibf/in2) and  the 
normal  pressure  which may be  expected 
in the 
power  steering  system is 
77 kgf/cm2 (1100 Ibf/in2). 
2. Under  certain  fault  conditions of the hydraulic F:h 
pump it is possible  to  obtain  pressures up to g ;,::; 
105 kgf/cm2 (1500 Ibf/in). 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 replcnish, thc 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 nccessary. 
6. Assemble  the test  equipment  and fit to the vehicle 
as  illustrated. 
7. Open  the tap in the  adaptor. 
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 
should  be 
70 to 77 kgf/cm2 (1000 to 
1100 Ibf/in2). 
(b) With  the  engine  idling and the steering  wheel 
held  hard 
on full  lock,  the pressure  should be 
28 kgf/cm2 (400 Ibf/in2) minimum. 
-4 
p: &. *,;:: .s 
Thesc checks  should  be carried  out first on one  lock, 
then 
on the other. 
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. 
10. Release  the steering  wheel and allow  the engine to 
idle.  The pressure  should be below 7 kgf/cm 
(100 Ibf/in2).  
						

							.. . 
STEERING 157 
11. If the  pressures  recorded during the  foregoing test 
are  outside  the specified  range, 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. 
ADJUST  POWER STEERING BOX - Adwest 
Lightweight  box 
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 
93 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. 
TEST  EQUIPMENT 
STl854M 
A. Steering  box 
B. Steering pump 
C. Existing hose  from steering  box 
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 
wheel  chocks. 
6. Road test the vehicle. 
.. ... . I. .... . .,. . l:: ::,.,. .. 
31  
						

							STEERING 
GEMMER POWER STEERING BOX OVERHAUL 
Special  tools: 
Drop  arm puller 
MS 252 A 
End cover  wrench  adaptor LST123 
Input shaft oil seal  installer LST124 
Sector  shaft oil seal  installer LST125 
Valve  seal installer  and valve  ring compressor LST126 
Preload  setting tool R01016 
Dismantle 
1. Remove  the steering  box from  the vehicle. 
2. Bend  back the  locking  tab and  remove  the drop 
arm  nut. Using  special 
tool MS 252 A or a suitable 
alternative,  withdraw the drop  arm from  the sector 
shaft. 
3. Using  special  adaptor  tool LST123 turn the 
cylinder cover  anti
-clockwise to expose end of the 
locking  ring. Now  turn the cover  clockwise  to 
extract  the ring. 
5. Slacken  the grub  screw  securing  the rack  pad 
adjuster. 
ST1811M ST1813M p *. 
4. To remove the cover, turn the  input shaft to the left 
lock for a LHD  drive  steering  box or to the  right 
for  a RHD  drive steering  box until  the rack  piston 
pushes  the cover  out to enable it to  be withdrawn 
by  hand. 
With a screwdriver remove the rack pad 
‘0’ ring  and spring. 
ST1815M f?; 
c_/ 
continued 
32  
						

							*.-> ,.. ,,.. ... .* c.;i:,.,] ,. . ... .. - ... . ..,.:e 
STEERING 157 
7. Restrain  the  sector shaft adjuster  with a 6 mm 
8. Remove  the six bolts  securing  the  sector shaft 
hexagonal 
key and remove  the locknut. 
cover. 
ST1816M 
9. Hold the  sector  shaft cover  and turn  the adjuster 
and  screw  clockwise  until 
the cover can be 
removed. 
10. Lift-out the  sector shaft. 
. ,.I.. . .. . 
ST 
11. Remove the  rack and piston  assembly  and collect 
the  rack  adjuster thrust  pad. 
ST 1819M 
12. Drive-out the worm  adjusting  screw locking  pin. 
13. Using  special tool LST123, remove the input  shaft 
worm  adjusting  screw anti
-clockwise. 
14. Tap the spiined end of the  input  shaft  to  free the 
outer  bearing.  Remove  the bearing  track and ball 
cage assembly. 
33  
						

							57 
15. Withdraw the  input  shaft,  worm and valve 
assembly. 
STEERING 
15 
ST1822M 
16. Release  the circlip  and remove  the  steel  washer 
17. Remove the wire  circlip, anti-extrusion  washer and 
and 
oil seal from 
the sector  shaft housing. 
Qil seal from the input  shaft housing. 
Sector  shaft assembly 
5. Check  that no side  play  or wear  exists  in the roller. 
6. Check  the condition  of the  adjuster and  its retainer 
7. The  axial  clearance of the adjuster  should not 
8. Examine  the bearing  journals on the shaft for  wear 
9. Check  the gear teeth  for  excessive and uneven 
and that 
the crimping 
is sound. 
exceed 
0,20 mm (0.008 in). 
and  damage. 
wear,  scores  and pitting. 
continued 
ST1949M I I 
INSPECTION AND OVERHAUL OF COMPONENTS 
Steering  box housing 
1. Examine  the sector  shaft  upper  and lower needle 
roller bearings  and 
if necessary drive them from the 
housing with  a suitable  drift. 
2. Inspect the  input  shaft  needle bearing  and if worn 
drive  it from  the housing  and press-in  a 
replacement. 
3. Examine  the piston  bore for wear and scores. 
4. Check  the input shaft  bores for wear and scores. 
ST1954M 
34  
						

							STEERING 157 I 
Valve and worm  assembly 
NOTE: If the  inner  ball race  is faulty  and unfit for 
further  service it cannot  be renewed  and a new  valve 
and  worm  assembly  must be obtained  and fitted.  Should 
this  be the  case,  the following  checks of the  valve  and 
worm  can be  ignored. 
10. Examine  the  valve  rings  which  must be free  from 
cuts,  scratches  and scores. 
Also, the rings  should 
be  a loose  fit 
in the grooves. 
11. If  any  ring  is unsatisfactory,  all the  rings  must be 
renewed.  When removing 
the rings take care  not to 
damage the  valve grooves. 
12. To fit new  rings  use  special  tool LST126, which 
consists 
of the  following  three parts:- 
a) Ring  expander. 
b)  Split 
collcr. 
c) Ring  compressor. 
Before  using the tool 
lubricatc each  part with  the 
recommended power  steering fluid. 
13. Warm the five  rings  in hol water  leaving  them in 
the  water  until ready  for fitting.  When pliable, feed 
the  ring  for  the 
Iowcr groove  (nearest  the roller 
bearing)  over 
thc expander  and  position the 
expander  over 
the input  shaft,  slide thc ring into 
the  groove  and mould 
it into  position  with the 
fingers. 
13 
A 
ST1941 M 
14. Encircle the ring  with  the split  coller  and squeeze 
the  coller  together,  by hand,  and hold  for 
approximately thirty seconds. 
15. Remove  the split  coller  and  with care,  ease  the 
compressor  tool over 
the ring  and leave  for a fcw 
minutes to cool  before  carefully rcmoving the tool. 
ST1942M 
5 
16. Using  the  expander  tool, as  before,  fit  the 
remaining  four rings,  one at a time,  into  the 
grooves  and mould  with the fingers.  It is important 
that 
only one  ring  at a time  is placed on the 
expander  since in the  meantime  the  remaining 
rings  could  cool in an  expanded  condition making 
it 
difficult to locate and contract thc rings in thc valve 
grooves.  Encircle the 
four rings with  the split coller 
and  squeeze  together 
for approximately  thirty 
seconds.  Then, with care,  ease the compression 
tool over  the four  rings  and allow  to cool  for about 
five  minutes  before carefully  withdrawing  the 
compressor. 
continued 
.- ._ .. .. _..‘ . .. 6.; .; .. . 
35  
						

							1571 STEERING 
17. Examine the bearing  surfaces of the valve  assembly 
for  wear  and scores. 
18. Examine  the worm track for  wear and pitting. 
19. Check  that  the  end-float between  the locator  and 
valve  sleeve  does not exceed 
0,12 mm (0.005 in). 
20.  Rotary  movement  between  the  components at the 
trim  pin 
is permissible. 
21. Check  that no free movement  exists on the  torsion 
bar  assembly  pin between 
the input  shaft and 
worm. 
29. Remove  the plastic  seal and the ‘0’ ring  seal 
30. Ensure that  the outer diameters  of the  piston  are 
31. Fit a new ‘0’ ring seal to the  piston groove. 
beneath 
it, from  the piston groove. 
free from  burrs  and damage. 
R0 
17 I 
ST1957M 18 20 19 
ST1955M 
22. The  valve  and worm  assembly should  be renewed if 
there  is wear  at the  following points: 
a)  Inner  and outer  bearing  tracks. 
b)  Worm. 
c) Valve  locator. 
d)  Input  shaft needle  bearing  Journal. 
23.  Examine  the outer  ball race and track  for wear  and 
general  condition.  The race  should  be renewed 
if 
there  is wear  and pitting  or if a new valve  and worm 
assembly 
is being  fitted. 
Thrust  pad and adjuster 
24. Examine the  thrust pad for scores. 
25. Check  that the thrust  pad seat  in the  adjuster  is not 
26.  Check  that the thrust  pad spring  is not  broken. 
worn 
or scored. 
Rack  and piston 
27. Examine the  rack teeth  for wear and  pitting. 
28. Check that the surface  on which  the thrust  pad 
bears  is not 
worn and  scored. 
32. To fit a new  plastic  seal to the  piston, warm  the seal 
in  hot  water  and 
fit to the  piston groove.  Insert  the 
piston  in the inverted  position 
i.e. piston  first into 
the  cylinder  and leave 
to cool. 
Sector  shaft cover 
33. Examine the sector  shaft cover needle  bearing  and 
if necessary extract the bearing  taking care not to 
damage  the housing. 
continued 
36