Land Rover Defender 90 110 Workshop Book 4 Rover

							STEERING 
34. Drive-in a new  bearing, up to the  shoulder,  with 
the  bearing  number  and  chamfered ends of the 
rollers trailing. 
35. Fit a  new ‘0’ ring seal to the cover. 
36. Check  that  the  cover  bearing  lubrication  passage 
and  bleed  nipple 
hole is clear. 
57 
. :.I..: .. . ... ... .. , 
ST 1 
2. Fit the  sector shaft  upper needle  bearings, number 
outwards, up  to the  shoulder. 
ST 
Fitting the valve  and worm assembly (input shaft) 
3. Fit the  input  shaft to the  steering  box housing  and 
lubricate  with the recommended  fluid. Turn the 
shaft  to the  straight  ahead position. 
Assemble 3 
During  the  following assembly  instructions  absolute 
cleanliness  must  be observed. 
Also when  fitting 
components  and 
oil seals they must only be lubricated 
with  the recommended  fluid,  or petroleum  jelly. 
1. If removed,  fit the  sector  shaft  lower  needle 
bearings,  numbers outwards,  to the steering  box 
to 
just below  the chamfer. 
ST1933M 
4. Fit the input shaft outer  bearing  and track. 
5. Lubricate  and fit the  input shaft cover  and ‘0’ ring 
seal  using  special tool 
LST123. 
ST1934M ST1931M 
..I .. .,. ....-. . . .I. I , .. , ..... :’ 
37  
						

							57 
S7 
STEERING 
6. Secure preload  setting tool R01016 to the  input 
shaft  with the  grub  screw. Wind  string  round the 
tool  and tie a spring  balance  to  the free end 
of the 
string.  Whilst turning  the  input shaft cover 
clockwise,  pull the spring  balance  until  a  constant 
preload  reading 
of 0,69 Nm is achieved. 
6 / 
Fitting sector shaft and piston-rack assembly 
7. Fit the  sector  shaft to the housing  and  engage it 
with the input  shaft worm  in the  straight  ahead 
position. 
8. Screw-on,  to the  sector  shaft adjuster,  the sector 
shaft  cover  and secure  with two or three 
of the six 
retaining  screws. 
9. Turn the adjuster  screw  clockwise,  with a  6 mm 
hexagonal  key, until  the sector  shaft  just  makes 
contact  with the input shaft worm. 
W ST1937M 
10. Without  moving the adjuster,  fit the  locknut  whilst 
restraining  the  adjuster  screw with the 
6 mm key 
and  just  nip  the  locknut with an  open
-ended 
spanner. 
ST1938M 
11. 
12. 
13. 
Temporarily  fit the  drop  arm and tighten the 
locknut  until no clearance is felt between  the sector 
shaft and  drop arm. 
Rotate  the  input shaft one turn  clockwise,  then 
turn  the  shaft  back to the  straight  ahead position 
whilst  noting  the point  at which  the backlash 
to the 
drop  arm disappears 
or is taken-up. 
Repeat  instruction 
12 and rotate  the input  shaft 
anri-ciockwise on to the  opposite iocic. 
38  
						

							~ . .. .. . .. ... 
... .. ..,, .- /. . 
STEERING 1571 
14. 
If the  difference  between  the two  points  at which 
the  backlash  is taken
-up  or disappears  is greater 
than 
90 (94 of a  turn)  it will  be necessary  to change 
the  shimming  behind the input  shaft inner  bearing 
cup. 
15. If  the  shimming  requires adjustment,  add a shim  on 
right
-hand  drive  steering  boxes if backlash starts 
too  quickly  on clockwise  rotation. Should backlash 
start 
too quickly  for anti-clockwise  rotation, 
remove  a  shim. 
For a  left-hand drive steering  box, 
reverse  :he foregoing  procedure. 
* 
NOTE: If it is necessary  to perform instruction 15, 
instructions 3 to 13 must be repeated afterwards. 
16. Remove the drop  arm  and whilst  restraining  the 
sector  shaft  adjuster, 
so that it does  not turn, 
remove  the locknut. 
17.  Remove  the sector  shaft  cover  screws  and while 
still  restraining  the  adjuster,  unscrew  clockwise, 
the  cover  from the sector  shaft  and  withdraw  the 
sector shaft. 
18. Lubricate  the rack  piston  plastic  seal and insert the 
piston  into the piston  bore, rack end first,  as in 
instruction 
11 of the  dismantling  procedure, to a 
depth 
of 37 mm below  the lip of the bore. 
19. Lubricate  and fit :he  sector  shaft in the straight 
ahead  position. 
20.  Lubricate  and  fit 
0 ring  seal to the  sector  shaft 
cover. 
21.  Restrain the sector  shaft adjuster  and screw
-on the 
cover,  reversing  instruction  17.  Secure with the six 
bolts,  tightening  evenly  to 
25 to 30 Nm (18 to 
22  lbs  ft). 
22.  Restrain  the  sector  shaft  adjuster  and fit and 
tighten  the locknut,  as instruction 
10. 
23.  Fit  and  lubricate  an 0 ring  seal  to  the rack 
adjuster  screw. 
24.  Fit the  rack  pad and  spring  noting that the larger 
flat  side  of the pad 
is towards the rack. 
25.  Screw
-in the  rack  pad adjuster  until the head  is 
4 mm from the steering  box face. 
I ST1943M 
39  
						

							1571 STEERING 
26. Lubricate  and fit an ‘0’ ring  seal to the piston-rack 
cover. 
27. 
Fit the  piston  cover  to  steering  box.  Align the 
retaining  ring hole  in the  cover  with the cut
-out  in 
steering  box housing  and  insert  hooked  end 
of the 
retaining  ring in the 
hole. Using  special  tool 
LST123, rotate the cover  anti-clockwise  to feed  the 
ring  into  the  groove  until the ring  is fully  seated. 
This 
is a reversal of instruction 3 of the  dismantling 
procedure. 
. 
ST1956M  
28.  Temporarily fit the drop  arm and secure  with the 
nut 
so that no backlash  is present  between  the arm 
and  sector  shaft.  Set the steering  in the  straight 
ahead  position. 
29. Fit the prcload  setting tool R01016 to the  input 
shaft  and  secure  with the  grub  screw. Rotate  the 
input  shaft in both  directions  clockwise and  anti
- 
clockwise % to 3/4 of a turn  to check  the backlash 
distribution. 
30. To check  the drop  arm  angular  travel for a LHD 
drive  steering  box use the preload  setting  tool  to 
turn  the input  shaft  two turns  clockwise  and  one 
and  three
-quarter  turns anti-clockwise.  For RHD 
drive boxes, the opposite applies. 
31. Remove the drop arm. 
32.  Return 
to the straight  ahead position  and screw  the 
rack  adjuster  clockwise  until  the adjuster pad  just 
contacts the  pad.  33. 
Restrain  the sector shaft  adjuster, as in instruction 
10, and  tighten  the locknut  to 70 to 90 Nm (52 to 
66 Ibs/ft). 
34.  Secure  the  rack adjuster  with the grub  screw, 
reversing  the dismantling  procedure instruction 
5. 
ST 
35. Secure the worm  adjuster  with a new  pin. If 
necessary,  drill  a new 
4 mm hole in the  adjuster 
through  the hole 
in the  steering  box housing to 
locate  the pin.  Check, before  drilling that the new 
hole  will not break  into the side  of the  existing 
hole. 
40  
						

							STEERING 
n 
57 
/ 
ST1947M 
Fitting sector shaft oil seal 
40. Lubricate  the oil seal  and seal-saver LST12.5, and 
slide 
the seal  over  the tool,  lip side leading. 
fully home into  the housing. 
41. Using  the seal-driver  part of the tool,  push thc seal 37. Withdraw  the conical  seal-saver  and  place  the 
lower  part 
of the tool  with  the seal,  lip side 
downwards,  over the input  shaft. 
38. Place the seal-driver  part of the tool on top of the 
seal  and drive 
it fully home. 
ST1948M 
38 
ST1950M 
42. Fit the  steel washer  and  secure the  assembly with 
the  circlip. 
39. Fit the  anti-extrustion  washer  and secure  the 
assembly  with the wire circlip. 
42 
ST1951M  I 
41  
						

							STEERING 
43. Fit the  drop  arm,  tab washer  and nut.  Tighten  the 
nut  to 
170 to 180 Nm (125 to 132 Ibs/ft). Fold  one 
side 
of the  tab  washer  over the drop  arm and the 
other  over a flat  against  the nut. 
44. Refit  the steering box to the  vehicle  and bleed  the 
hydraulic  system. 
NOTE: Bleeding and test of the power steering box 
is the same  as that for the Adwest Lightweight box. 
42  
						

							w ,. ,., 
, ..... .. .,. ., ... .,, . .. ... 
STEERING 157 
SYMPTOM 
INSUFFICIENT POWER 
ASSISTANCE  WHEN 
PARKING 
POOR HANDLING 
WHEN  VEHICLE  IS 
[N MOTION 
3YDRAULlC FLUID ,EAKS 
3XCESSIVE NOISE 
:RACKED STEERING 3ox 
POWER STEERING 
FAULT DIAGNOSIS 
P CAUSE 
(1) Lack of fluid. 
(2)  Engine  idling speed  too low. 
(3) Driving  belt slipping. 
(4) Defective hydraulic  pump and or prcssure  relief valve. 
Lack  of castor action. 
Steering  too light 
and/or over- jensitive. 
Damaged  pipework,  loose :onnecting unions, etc. 
:I) If thc high pressure  hose is allowed  to come  into contact 
with  the body shell, or any component not  insulated  by 
the  body mounting,  noise  will 
be  transmitted  to the  car 
interior. 
2) Noise  from hydraulic  pump. 
Zxcessive pressure due to faulty ,elief valve in hydraulic  pump.  ~~  ~  ~  ~~ 
TEST ACTION 
Check 
hydraulic  fluid tank level. 
Try assistance  at fast  idle. 
Check  belt tension. 
(a) 
Fit pressure gauge between 
high  pressure  hose and  steering 
pump,  with steering  held 
hard  on full  lock, see  Note 
1 below, and Power  steering 
pump  test. 
[b) Release steering  wheel and 
allow  engine  to Idle.  See 
Power  steerine 
Dumu test.  ~  ~  ~~  ~~~  ~~  ~  ~~ 
llis is 
caused  by over-tightening :he rocker shaft  backlash adjusting mew on top of steering box. 
:heck for loose torsion  bar fixings In stecring  box valve  and worm assembly. 
:heck by visual  inspection;  leaks 
rom  the high  pressure pipe  lines 
ire  best  found  while holding  the 
;teering on full lock with engine wnning at fast  idle speed  (see Jote 1 below). xaks from the steering  box tend o show  up under  low pressure :onditions, that  is, engine  idling md no uressurc on steering wheel. 
heck  the 
loose runs of the hoses. 
:heck oil level  and bleed svstem.  ~~ 
Zhcck by visual 
inspection. 
CURE 
If low, fill and  bleed thc system. 
If necessary, reset idle specd. 
Adjust thc driving  belt 
If pressure  is outside  limits (high or low) after  checking items 1 and 3, see Note 2 below. 
If  pressure  is greater,  check 
steering  box for freedom and 
self
-centring  action. 
It  is most  important  that this 
screw 
is correctly  adjusted. See 
Instructions  governing adjustment. 
Fit  new  valve  and worm  assembly. 
Tighten 
or renew as nccessary. 
4lter hose routc or insulatc as 
necessary. 
if no cure, change hydraulic  pump. 
Pit  new steering  box and 
rcctify iydraulic pump or replace as 
iccessary . 
Jote 1. Never hold  the steering  wheel  on full lock for more than 30 seconds  in any  one  minute,  to avoid causing the oil to overheat  and possible 
damage  to the seals. 
riotc 2.  High  pressure- In general  it may  be assumed  that excessive pressurc is due to a faulty relief  valve  in  the hydraulic  pump. 
Low  pressure - Insufficient  pressure may be caused by one of the  following: 
1. Low fluid level in  reservoir Most  usual cause of 2. Pump belt slip } insufficient  pressure 3. Leaks in the  power steering  system 4. Faulty relief valve  in the  hydraulic  pump 5. Fault in steering box  valve and worm  assembly 6. Leak at piston sealing  in steering  box 7. Worn components in either stecring  box or hydraulic pump 
43  
						

							OVERHAUL DROP ARM BALL JOINT 
. 
The drop  arm ball joint  can be overhauled and  there is 
a  repair  kit available  which consists 
of the following 
items. 
Ball  Pin  Ball lower socket 
Retainer  Spring 
Spring  rings 
‘0’ ring 
Dust  cover  Cover plate 
Ball  top socket  Circlip 
Dismantle 
1. Remove the drop  arm  from  the vehicle  and clean 
the exterior. 
2. Remove  the  spring  rings and prise-off the  dust 
cover. 
3. In  the  interests of safety,  position  the ball  joint 
under  a press  to relieve  the spring  tension  and 
support  the  housing  both  sides 
of the ball  pin,  as 
illustrated.  Apply  pressure to the  cover  plate  and 
remove  the circlip 
and slowly release  the pressure. 
WARNING: Personal injury could result  if the circlip is 
removed without pressure being applied  and maintained 
to the  cover  plate. 
4. Remove the  spring, top socket,  and ‘0’ ring. 
ST1382M 
ST138lM 
KEY TO BALL JOINT 
1. Spring  rings. 7. Topsocket 
2. Dust cover. 8. Spring. 
3. Ball housing. 9. ‘O’ring. 
4. Retainer. 10. Cover  plate 
5. Bottom socket. 11. Circlip. 
6. Ball pin. 
44  
						

							STEERING 
. I !. 5. Since the ball  pin cannot  be  removed  with the 
ball  pin  to release  the  retainer  and to remove  the 
pin  from  the housing. 6. Using  a  sharp-edged  punch  or chisel,  drive  the 
i: 4- retainer in position,  tap the  threaded  end  of the  ball lower  socket  from the  housing.  Should 
difficulty  be experienced,  apply gentle  heat to the 
housing  and  then  continue  to  drive the socket 
from  the housing. 
7. Clean  the housing  and remove  any burrs. 
Assemble 
8. Press-in the  lower  socket  squarely  up  to the 
shoulder. 
9. Dip the ball  in Duckhams LBlO grease,  or 
equivalent  and fit to  the  housing  and pack  with 
grease. 
10. Fit  the  top  socket. 
11. Fit the  spring,  small diameter  towards the ball. 
12. Fit the ‘0’ ring  and using  the same method  as for 
removing the circlip  and compress  the cover  plate 
and  secure  with the circlip.  Ensure that  the  circlip 
is fully  seated in the  machined groove. 
13. Press  the retainer  on to the ball  pin so that  the top 
edge  is level with  the edge 
of the taper. 
14. Fit the  dust  cover  and retain  with the  two  spring 
rings. 
ST1383M 
57 
ST 1384M 
15. Fit  the  drop akrn to the  steering  box  using  a new 
lock  washer.  Tighten  the retaining  nut 
to the 
correct  torque and bend  over the lock  washer. 
16. Assemble  the  ball  pin to the  drag  link,  see 
instructions  for fitting  drag link and  track  rod, and 
tighten  the castle  nut 
to the correct  torque and 
secure  with a new split  pin. 
45  
						

							El STEERING 
TRACK ROD AND DRAGLINK - All Models 
When adjusting  or renewing a track  rod or draglink it is 
important to ensure  that the ball joints  are assembled in 
the  same  angular  plane and that  the ball  joint  pins are 
central 
in their  respective  housings,  as  example ‘A’ 
illustrated  below. Premature wear could  result if the 
pins are inclined  to one-side  as illustration B. 
CAUTION: A track rod  or draglink  that is damaged or 
bent  must  be renewed.  No attempt should be made  to 
repair 
or straighten  it. 
46