Land Rover 90 110 Workshop Rover Manual

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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  
						

							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  
						

							,