Land Rover Defender 90 110 Workshop Book 4 Rover

							SUSPENSION 
OVERHAUL FRONT HUB ASSEMBLY ., i I. .. . i x- - * Service tools: 
Drift 
18G 134 
Hub  oil seal  replacer 
1SG 1349 
Dial  gauge  bracket 
RO 530106 
DISMANTLE 
13. Remove the  key washer. 
14. Withdraw  the hub  and brake  disc  assembly 
complete  with bearings. 
15.  Remove the  outer bearing. 
16. Mark,  for reassembly,  the relationship between the 
17. Remove  the  five bolts  and  separate  the hub  from 
hub 
and brake  disc, 
if original  hub is to  be  refitted. 
the  brake  disc. 
1. Slacken  road wheel  nuts. 
2.  Jack  up the  vehicle  and lower  onto axle stand. 
3.  Remove  the road wheel. 
4. Slacken the lock  nuts  securing  the jump  hose to the 
retaining bracket.  continued 
5. Remove  the two  bolts securing the  brake  caliper 
and  whilst  withdrawing  the caliper  from the brake 
disc  release  the jump  hose from  the bracket. 
Tie 
the caliper  securely  to one  side. 
NOTE: The  road  wheel  retaining studs must not be 
renewed.  Should any studs  be unservicable  a new 
hub  complete  with studs  must be obtained. 
KEY TO HUB ASSEMBLY 
NOTE: Since  the bracket on later  vehicles  is not 
completely. 
1 open-ended,  the caliper  must be removed 
6. Lever-off the  dust cap. 
7. Remove the  circlip from the drive  shaft. 
8. Remove  the drive shaft shim. 
9. Remove  the five bolts  and  withdraw the driving 
member  and joint washer. 
10. Bend  back the lock  washer  tab. 
11. Remove the  locknut and tab washer. 
12.  Remove the hub  adjusting nut. 
1. Dust cap. 
2. Drive  shaft circlip. 
3. Drive shaft shim 
4. Drive member. 
5. Drive member joint washer. 
6. Drive  member  retaining  bolt (five  off). 
7. Locknut. 
8. Lock washer. 
9. Hub  adjusting  nut. 
10. Keyed washer. 
11.  Outer 
bcaring. 
12.  Hub. 
13. Inner  bearing. 
14.  Grease  seal. 
15. Brake disc. 
ST633M  
						

							SUSPENSION 
18. Drift-out  the  grease  seal  and  inner  bearing  from 
19.  Drift
-out the inner  and outer  bearing tracks.  22. 
With  the lip side  leading 
fit a  new  seal  to the hub 
using  special  tool 
18G 1349 grease  seal replacer 
and  drift  18G  134. 
Drive-In the seal so that it is 
recessed 
4,83 to 5,33 mm (0.190 to 0.210 in)  below 
the  rear  face of the  hub.  Apply  grease  liberally 
between  the  seal lips and springs. 
the 
hub and  discard the seal. 
pJ 
2 
ST631M 
23. Assemble  the  brake  disc to the  hub  lining up the 
marks made during dismantling. 
Fit and  tighten  the 
five  retaining  bolts to 65  to 
80 Nm (48  to 59  Ibf  ft). 
24.  Grease  as 
in instruction 21 and fit the outer  bearing 
to the hub. 
25.  Clean  the  stub axle and drive shaft  and 
fit the hub 
assembly 
to the axle. 
26.  Fit the  key  washer. 
27. 
Fit the  hub  adjusting  nut and tighten by hand  whilst 
rotating  the hub  until  all end
-play is taken  up. 
28.  Mount  a dial  gauge 
using bracket RO 530106  and 
rest  the stylus  in a loaded  condition 
on the 
adjusting  nut. 
ASSEMBLE 
20. Clean and degrease the hub  and drift-in the  inner 
and  outer  bearing  tracks. 
continued 
ST6 
21. Pack  the  hub  inner  bearing  with a grease 
recommended 
In the  lubrication  chart and fit to the ST6*lM 
hub.  Use a minimum of 8,5 grams of grease. 
2  
						

							SUSPENSION 164 I 
.;I-.~~ t-.y . 29. Slacken off the adjusting  nut  until an end-play  of 
0,1270  to 
0,1016 mm (0.0005 to 0.004 in) is 
obtained. *- -%E,- 
30.  Fit a new  keyed  lock tab washer. 
31.  Fit and  tighten  the hub  adjusting  nut and  re
-check 
the  end
-play  before bending  the lock  tab over. 
32.  Fit  a new  joint  washer  to the  driving  member  and 
fit  the member  to the  hub  and secure  with the five 
bolts  tightening 
evcnly to 60 to 70 Nm (44 to 
52 Ibf ft). 
33.  Fit the  original  drive shaft  shim and secure  with the 
circlip. 
34. To check  the  drive  shaft  end-play mount  a dial 
gauge  using bracket 
RO 530106  and rest  the stylus 
in a loaded  condition  on the end of the drive shaft. 
35.  Fit a suitable  bolt to the threaded  end 
of the drive 
OVERHAUL  STUB AXLE,  AXLE SHAFT, 
CONSTANT  VELOCITY JOINT AND SWIVEL 
ASSEMBLY 
Special  tool: 
18G 284AAH bush extractor 
Remove  stub axle,  axle shaft 
and constant  velocity joint 
1. Remove  the  hub  complete  as described  in the 
operation  to overhaul  the hub  assembly 
instructions 
1 to 14. 
2.  Drain  the swivel pin  housing and  refit plug. 
3. Remove the six bolts  retaining  the stub  axle to the 
4. Remove  the mud shield. 
5. Remove  the stub axle and joint  washer. 
swivel 
housing. 
. ,.. /. ... i:. 
.. .. . . . ,. .. . 
shaft and  using a pair of pliers move  the drive shaft 
back  and  forth  noting the dial  gauge  reading. The 
end
-play  should  be  between  0,127 to 0,254 mm 
(0.005 to 0.010 in). 
6. Pull-out the  axle  shaft  and constant  velocity joint 
from  the axle  casing. 
continued 
*. . . 
36. If the  end-play  requires  adjustment, remove the 
circlip,  measure  the shim  thickness  and fit an 
appropriate  selective shim 
to give the required 
end
-play. 
37. Remove the  bolt from  the drive  shaft, fit the circlip 
and  dust  cap. 
38.  Fit  the brake  caliper  and tighten  the two  bolts 
to 
120 to 150 Nm (88 to 111 Ibf ft). 
39.  Locate  the jump 
hosc in the bracket  and tighten 
the  locknuts. 
40. Fit  the  road wheel,  remove  the axle  stand  and 
finally  tighten  the road  wheel  nuts. 
41. Operate  the footbrakc  several  times  to locate  the 
brake pads  before taking 
the vehicle  on the  road. 
3  
						

							64 
Remove constant  velocity joint from axle shaft 
7. Hold the  axle shaft  firmly  in a soft  jawed  vice. 
8. Using  a soft  mallet  drive the constant  velocity joint 
9. Remove  the circlip  and collar from the axle  shaft. 
from 
thc shaft. 
SUSPENSION 
.e I 
12. 
13. 
i4. 
15. 
16. 
17. 
18. 
Swivel 
the cage  into line  with  the axis of the joint 
and  turn 
is until  two  opposite  windows coincide 
with  two lands 
of the joint  housing. 
Withdraw  the cage. 
Turn  the inner track  at right  angles  to the cage  with 
two 
of the  lands  opposite the cage openings  and 
withdraw  the inner race. 
Degrease  and  examine  all components  for general 
wear  and condition. 
Examine the  inner and outer  track,  cage balls  and 
bearing  surfaces 
of the  constant  velocity joint for 
damage  and excessive  wear. 
To assemble the  constant velocity joint, reverse  the 
dismantling  instructions  and lubricate  with a 
recommended 
EP oil. 
Check  that  the  end
-float of the assembled  joint 
does not  exceed 
0,64 mm (0.025 in). 
continued 
Dismantle  the constant  velocity joint 
10. Mark the relative  positions  of the constant  velocity 
joint  inner  and outer  race and the cage  for  correct 
reassembly. 
11. Tilt  and  swivel  the cage  and inner  race to remove 
the balls. 
- 12 
ST1025M 
14 
ST1026M 
4  
						

							SUSPENSION El 
. 
, 9, Fit constant  velocity joint to axle 
19.  Fit the collar  and a new circlip. 
20. Engage  the constant  velocity joint on the  axle shaft 
splines  and using  a soft  mallet,  drive  the  joint 
home. 
I ST636M 
1( 
Renew stub axle intermediate oil seal  and  bush 
21. TO remove  the bronze  bush and oil seal use special 
tool 
18G 284AAH and a slide  hammer.  Ensure 
that  the fingers 
of the  tool locate behind  the oil seal 
so that  the seal  and  bush  are driven-out  together. 
22.  Lubricate  the seal  and lip with 
EP90 oil and  with 
the  cavity  side 
lcading press-in a new  intermediate 
oil seal using  a suitable tube. 
23.  Using a  suitable block, 
press or drive-in the  bush 
up  to 
the shoulder. 
Remove swivel  pin housing 
24. Remove  the  brake disc shield  secured  by one nut 
and  bolt  at the bottom  front,  and one  single  bolt, 
behind  the shield,  in the  swivel  housing. 
25.  Disconnect  the  track
-rod end  ball joint  from  the 
housing. 
26.  Disconnect  the 
drag-link ball joint. 
27.  Remove  the seven  bolts securing  the swivel  pin 
housing  oil seal  and retaining  plate  and joint 
washer  and release  the assembly  from 
the swivel 
pin  housing.  Note  that  whilst the joint  washer  can 
be removed  at this  stage,  the oil seal  and retaining 
plate  must 
remain until the swivel  pin bearing 
housing  is removed.  28. 
Remove  the  two  bolts, complete  with the brake 
disc  shield  bracket,  securing  the lower  swivel  pin to 
the  housing. 
29.  Withdraw  the lower  swivel  pin and  joint  washer  by 
tapping the  small protruding  lug. 
30.  Remove the  top swivel  pin retaining  bolts complete 
with  the brake  jump hose bracket. 
31. Withdraw  the top  swivel  pin and  shims. 
32.  Remove  the  swivel  pin housing whilst retrieving 
the  lower  taper bearing. 
33. If the swivel  pin housing  is to  be  renewed,  remove 
the  drain  and level  plugs  and lock
-stop  bolt  and 
nut. 
Remove swivel pin bearing housing 
34.  Remove  the  seven bolts  securing  the swivel  pin 
bearing  housing 
to the axle  case  and  remove  the 
housing  and joint  washer. 
35.  Remove  and discard 
the swivcl pin oil seal  and 
joint  washer. 
Overhaul swivel pin bearing housing 
36. Prise-out the oil seal  from  the back of the housing. 
37. Drift-out  the lower  swivel  pin bearing  track. 
38.  Press
-out  the  upper  swivel pin in Railko  bush 
39. If worn, pitted  or damaged,  renew thc housing. 
40.  Press
-in  the  lower  swivel  pin bearing track. 
41. Press-in the Railko  bush housing  ensuring  that  the 
machined flat  is towards 
thc back of thc housing, ic 
when  the housing  is fitted  to thc axle, the flat  faces 
inboard. 
42.  With  the cavity  side trailing  press  the axle shaft oil 
seal  into  the housing and  grcasc. 
43. 
Fit the  thrust  disc into  the bottom  of the  Railko 
bush  housing  and check  that it is  still  in position 
when  the swivel pin  is fitted. 
housing. 
Fit swivel 
pin bearing housing to  axle 
44. Coat  the swivel  pin  bearing housing  to axle  casing 
bolts  with Loctite  270. 
45.  Coat  both sides 
of a joint washer  and place in 
position  on the swivel  pin  bearing housing  to axle 
mating  face. 
46.  Hang 
the swivel  pin bearing  housing  oil seal, 
retainer  and  joint washer  over  the  back of thc 
housing. 
47. 
Fit and  secure the  swivel pin bearing housing to the 
axle with  the seven  bolts  tightening evenly to 65 to 
80 Nm (48 to 59  Ibf  ft). 
Fit swive! pi,n, hcusinn 6 
48.  Grease  and fit the lower swivcl  pin  bearing  to  the 
49.  Place  the swivel  pin housing 
in position  over the 
bearing 
housing. 
swivel 
in bearing housing.  continued 
5  
						

							,  
						

							SUSPENSION E( 
Tyrc Size 
750 x 16 Michelin XS 
750 x 16  Avon  Rangers 
750 
x 16  (All  others) 
c J I. .; 50. Coat  a joint  washer  both sides  with sealing 
compound  and  place in position  on the  lower 
swivel  pin. 
51. Fit the  lower  pin with lip outboard. Do not  secure 
with  bolts  at this  stage. 
52. Lubricate  the Railko  bush with an EP  oil and  fit the 
top  swivel  pin  with  existing  shims and fit the 
securing  bolts and jump  hose  bracket  (do not 
tighten). 
53.  Coat  the threads  of the  lower  swivel  pin bolts  with 
Loctite  270 and  fit,  together  with the  brake  disc 
shield  bracket,  and tighten  to 
22 to 28 Nm (16 to 
21 Ibf ft). 
54. Tighten  the  top swivel  pin  securing bolts to 60 to 
70 Nm (44 to 52 Ibf ft). 
55. To check  the top  swivel pin  pre-load attach a spring 
balance  to the  track
-rod  ball  joint bore  and pull  the 
balance 
to determine the  effort required  to turn  the 
swivel.  The resistance,  once 
the initial  inertia  has 
been  overcome,  should be 
3,60 to 430 Kg (8 to 
10 Ibs). If necessary,  adjust by removing or adding 
shims 
to the  top  swivel pin  as required. 
ir .R ., ” *’ . ,.. 
% - 
Dim ‘A’ & 0,25 mm 
54,OO mm 
54,OO mm 
51.00 mm 
63. Fit the  stub  axle  with  the keyway uppermost at 
12 o’clock. At this  stage it is most  important  to 
ensure  that  the  constant  velocity joint bearing 
journal  engages  fully into the bronze  bush in the 
rear  of the  stub 
axlc before the stub  axle is secured 
with  bolts.  Damage  to the  bush  can occur 
if this 
precaution  is not  observed.  To ensure  proper 
engagement,  grasp the stub  axle with  one hand  and 
with  the other  pull the axle  shaft into the bush. The 
shaft  and bush  are correctly  engaged  when  the end 
of the axle  shaft  splines  are flush  with the  end of 
the  stub  axle. This condition  must be maintained 
during  all ensuing assembly  operations. 
64.  Place  the mud shield  in position and secure  the stub 
axle  to  the  swivel pin housing  with the six bolts 
using  Loctite  270 and  evenly  tighten  to 60 to 
70 Nm 
(44 to 52 Ibf  ft). 
65. 
To complete  the reassembly,  follow instructions 25 
to 41  covering  front hub overhaul. 
66.  Check  that the swivel  pin  housing  drain plug is 
tightly  fitted and remove the  filler level 
plug. 
67. Inject  approximately 0,28 litres (% pint)  of 
recommended 
EP oil  until  the oil begins  to run out 
of the filler hole. Fit and  tighten  the  plug  and wipe 
away  any 
surplus oil. 
68.  Set 
the steering  lock-stop  bolts  to providc a 
clearance  between  the tyre  wall  and  radius  arm in 
accordance  with the dimensions  below. This 
dimension  however, must  bc set to 56 
mm, 
irrespective  of tyre  size  and type where  steering 
gaiters  are fitted. 
56.  Liberally  apply 
- but  do not pack - a 
recommendcd grease  between  the lips of  the swivel 
oil  seal 
(2,5 to 4,O grams). 
57. Secure  the oil seal and joint washer  with the 
retaining  plate and securing  bolts tightening  evenly 
to  7 
to 10 Nm (5 to 7 Ibf  ft). 
58. Fit the  track-rod  and  drag  link and secure  with new 
split pins. 
59. Fit  the  brake  disc shield. 
60.  Loosely  fit the 
lock stop  bolt and  nut for later 
adjustment 
. 
-- 
ST18OlM Fit  drive  shaft and stub  axle 
61. Place  a new  joint washer  in position  on the swivel 
pin  housing  to stub  axle mating face. 
62. Taking care not  to damage  the axle  shaft oil seals, 
insert 
the axle  shaft,  and  when the differential 
splines  are engaged,  push the assembly  home. 
,. 
7  
						

							64 
OVERHAUL REAR HUB ASSEMBLY 
Service tool: 18G 1349 seal replacer 
Dismantle 
NOTE:  The 
oil catcher mentioned in instructions  7 and 
17, 
is fitted  to 110 models  only. 
SUSPENSION 
1. Slacken  the  road wheel retaining nuts,  jack  up the 
vehicle,  lower onto axle stands  and  remove the 
road  wheels. 
2.  Remove  the three brake  drum retaining screws and 
withdraw  the brake  drum. If necessary,  slacken the 
brake  adjuster to  facilitate removal. 
3. Lever off the hub  cap  and  remove  the axle  shaft 
circlip. 
4. Remove  the six bolts  and withdraw  the hub  driving 
5. Unlock the tab washer,  remove the outer and inner 
1 member and joint washer. 
locknuts  and keyed  thrust washer. 
6. Withdraw  the hub  complete  with inner  and  outer 
taper  roller bearings  and dual  lipped seal. 
7. If required,  remove  the oil catcher  and  bearing 
sleeve  by removing  the six brake  backplate 
retaining nuts  and bolts. 
Overhaul  hub 
8. Remove the dual  lipped  seal  and  inner bearing 
9. If new bearings  are to be fitted drift  or press  out the 
10. Examine  the road  wheel  studs and  renew any worn 
11. Press  in new  bearing cups  up to the  shoulder. 
12.  Examine  the oil seal  housing  in the  hub  and 
remove any  burrs that could  damage the  seal. 
13. Pack the inner bearing  with Shell Retinax A grease 
or  equivalent  and fit to the  hub. 
14.  While  taking  care not to touch  the seal  lips, 
liberally  smear 
- not pack - the cavity  between 
the  seal  lips with  Shell Retinax 
A or equivalent. 
from the hub. 
old bearing 
cups. 
or  damaged ones. 
$3 %*’ 
8  
						

							SUSPENSION 164 
15. To avoid possible  damage to the  seal  and to ensure 
the  correct  depth into the hub,  press
-in the  seal,  lip 
side leading,  using special  tool 
18G 1349.  16. 
If 
this tool 
is not  available  obtain a suitable  tube 
that  will 
fit exactly  on the four diametrically 
opposed  pads 
in the channel  round the seal  on the 
opposite  side to the  lip and 
with the  lip leading 
press
-in  the  seal so that it is recessed 4,s to 5,3 m 
(0.190 to 0.210 in) from  the rear  face of the  hub. 
.. . .. .. ... ,..,. , i ., . , , .. 
110 REAR  AXLE HUB 
2 
1. Dust cap. 10. Brake dru!??. 
2. Circlip.  11. Hub. 
3. Driving  member. 12. Outer bearing. 
4. Joint washer.  13. Oil seal. 
5. Locknut.  14. Oil catcher. 
6. Lock  washer. 
7.  Adjusting  nut. 
8. Key washer. 
9. Outer  bearing.  18. Half-shaft. 
15. 
Brake  back plate  assembly. 
16.  Stub  axle. 
17.  Joint  washer. 
9  
						

							SUSPENSION 
Reassemble hub to axle 
17. If removed,  assemble the backplate  and oil catcher 
to  the  axle  having  first  smeared  Hylomar 
SQ32M 
on the  face of the oil catcher  to seal  it  to  the 
backplate. Ensure  that the milled  slot and  the drain 
hole 
in the  backplate line up at the  bottom. Secure 
the  assembly 
to the  axle  with  the six bolts  and nuts 
and 
tightcn to  the  correct torque. 
ST503M 
18.  Before  fitting the hub, ensurc that thc journal  on 
which  the  dual  lipped  seal runs  is clean  and free 
from 
imperfcctions that  could  damage  the seal. 
19. Fit the hub  to the  bearing  sleeve, pack the  outer 
bearing  with grease  and fit 
to the hub. 
20.  Fit the  keyed  thrust  washer  and  adjusting inner 
nut.  Tighten  the nut,  by hand,  whilst  rotating  the 
hub  until  all the end
-play is taken up. 
21. Mount  a dial test  indicator so that the stylus rest  on 
the  adjusting  nut. Slacken the  nut back 
to obtain  an 
end
-float of 0,050  to 0,101 mm (0.002 to 0.004 in). 
22. 
Fit the  tab washer  and outer  locknut.  Tighten  the 
locknut,  re
-check the end-float and  lock the nuts. 
ST632M 
10 
23.  Using  a  new joint  washer,  fit the  hub  driving e 
member  and tighten  the retaining  bolts and spring *‘ 
washers  to 60 to 70 Nm (44 to 52  Ibf  ft). 
24.  Fit the  circlip  to the  axle  shaft,  ensuring  that 
it 
locates  correctly  in the  groove. 
25.  Fit  the  hub cap, 
if necessary  using a new ‘0’ ring 
seal. 
26.  Fit the  brake  drum and secure, 
if necessary  with 
new  screws. 
27.  Adjust  the brake  shoes to  the drum. 
28.  Fit the road wheels,  using new nuts 
if necessary. 
29.  Remove  the vehicle  from the axle  stands  and 
finally  tighten  the wheel  nuts to the correct torque. 
REAR HUBS 
With  inner  and  outer seals.  From axle numbers 
onwards 
Land Rover 
90 
Land  Rover  110 
22308284B 
21 S22955B 
REMOVE  AND OVERHAUL 
Special tools: 
Oil  seal  replacer 
LST 550-5 
Drift for seal replacer MS 550 or 186134 
Hub  nut spanner 606435 
Remove 
1. Jack-up  the  vehicle,  lower onto axle stands  and 
remove  the road  wheels. 
2.  Remove the  two brake drum  retaining screws and 
withdraw  the brake  drum. 
If necessary,  slacken  the 
brake adjuster  to facilitate removal. 
3. Prise-off  the hub  cap. 
4. Remove  the circlip. 
5. Remove  the  five bolts  and withdraw  the hub 
driving  member  and joint  washer. 
6.  Prise
-up  the  lock  washer  and remove  the  outer 
locknut  and inner  adjusting  nut. 
7.  Withdraw  the  hub  complete  with  with the inner 
and  outer  seals,  seal track  spacer,  and inner  and 
outer  taper roller bearings. 
8. If the  stub  axle is damaged  or scored  remove  and 
discard 
it by  removing  the six brake  back  plate 
retaining nuts and bo!ts. 
Overhaul  hub 
9. Remove the  seal track spaccr and outer  seal. 
10. Remove the outer bearing  cone. 
continued f ”’ ‘IJ