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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
Land Rover Defender 1999 2002my Workshop Supplement Body Repair 2nd Edition Rover Manual
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47PROPELLER SHAFTS 2 OVERHAUL PROPELLOR SHAFT - REAR Service repair no - 47.15.12 Remove 1.Remove rear propeller shaft.See Repair. 2.Thoroughly examine universal joint for signs of damage or wear. 3.Clean universal joint bearing cups and circlips. CAUTION: To ensure correct assembly and reduce possibility of imbalance, before removing propeller shaft joint mark position of spider pin relative to journal yoke ears. 4.Remove circlips. 5.Remove grease nipple. 6.Tap yokes to eject bearing cups. 7.Remove bearing cups. 8.Remove spider. 9.Clean yokes and bearing cup locations.Refit 10.Remove bearing cups from new spider. 11.Check all needle rollers are present and positioned in bearing cups. 12.Enter new spider with seals into yokes of propeller shaft flange. 13.Partially insert one bearing cup into flange yoke and enter spider trunnion into bearing cup. 14.Insert opposite bearing cup into flange yoke. 15.Press both cups into place. 16.Press each cup into its respective yoke up to lower land of circlip groove. Damage may be caused to cups and seals if cups pass this point. 17.Fit circlips and check no end float exists. 18.Fit grease nipple and lubricate. 19.Repeat instructions for opposite end of propeller shaft as described in 3 to 9. 20.Fit rear propeller shaft.See Repair.
57 - STEERING CONTENTS Page REPAIR STEERING COLUMN - UPPER - Td5 1.................................................................
STEERING 1 REPAIR STEERING COLUMN - UPPER - Td5 Service repair no - 57.40.01 Remove 1.Ensure road wheels and steering wheel are set in the straight ahead position. 2.Loosen 2 clips securing air inlet pipe between turbo and inlet air filter. 3.Remove air inlet pipe. 4.Mark relationship between the upper steering column and the lower steering column universal joint. 5.Remove bolt securing upper column to lower column universal joint. 6.Remove steering colum nacelle.See this Section. 7.Remove instrument pack.See INSTRUMENTS, Repair. 8.Disconnect 3 column switch multiplugs. 9.Loosen column switch clamping screw. 10.Remove column switch assembly from steering column. 11.Disconnect 4 Lucars from rear of ignition switch. NOTE: Take note of Lucars correct fitted position. Details can also be found in the Electrical Reference Library. 12.Remove passive coil.See ELECTRICAL, Repair. 13.Drill out 2 shear bolts securing ignition barrel to column. 14.Remove ignition barrel.
57STEERING 2 REPAIR 15.Remove brake servo.See BRAKES, Repair. 16.Release ABS modulator multiplug from side of brake pedal box. 17.Release mat from underside of fascia to gain access to brake pedal box mounting bolts. 18.Remove 6 bolts securing brake pedal box to bulkhead. 19.Disconnect 2 brake pedal switch Lucars. 20.Carefully remove brake pedal box assembly and collect gasket. 21.Remove bolt securing column upper tie bar to column. 22.Remove 2 bolts securing upper column to lower mounting bracket. 23.Remove 2 bolts securing 2 halves of column upper clamp. 24.Remove 2 bolts securing column upper clamp to mounting bracket. 25.Remove column upper clamp and collect rubber packing. 26.Remove 2 bolts securing column upper mounting bracket to bulkhead. 27.Release upper column from lower column and manouvre mounting bracket and upper column assembly from vehicle. 28.Remove mounting bracket from column.
STEERING 3 REPAIR Refit NOTE: The steering column is a non-servicable component and can only be serviced as a complete assembly. 29.Fit mounting bracket to column and manouvre assembly into position. NOTE: Ensure marks on upper and lower columns are aligned. 30.Loosely fit bolts securing mounting bracket to bulkhead. 31.Fit upper clamp and rubber packing to column. 32.Loosely fit bolts securing upper clamp to mounting bracket. 33.Loosely fit bolts securing 2 halves of upper clamp. 34.Loosely fit bolts securing column lower mounting bracket. 35.Fit bolt securing upper tie bar to steering column and tighten to22 Nm (16 lbf.ft). 36.Tighten mounting bracket to bulkhead bolts, clamp bolts, and lower mounting bolts. M6 bolts =9 Nm (6 lbf.ft) M8 bolts =22 Nm (16 lbf.ft) 37.Manouvre brake pedal box assembly and NEW gasket into position in vehicle. 38.Tighten bolts securing brake pedal box to bulkhead to25 Nm (18 lbf.ft) 39.Connect brake pedal switch Lucars. 40.Reposition mat to underside of fascia. 41.Secure ABS modulator multiplug to side of brake pedal box. 42.Fit brake servo.See BRAKES, Repair. 43.Fit ignition switch to steering column, ensuring inner shaft slot aligns with steering lock plunger. 44.Evenly tighten clamp bolts, but DO NOT shear at this stage. 45.Temporarily fit steering wheel and check for correct operation of switch and lock. 46.Remove steering wheel. 47.Fully tighten ignition switch bolts until heads shear.48.Connect Lucars to rear of ignition switch. 49.Fit passive coil to ignition switch and connect multiplug. 50.Fit switch assembly to steering column and tighten clamping screw. 51.Connect column switch multiplugs. 52.Fit instrument pack.See INSTRUMENTS, Repair. 53.Fit steering column nacelle.See this Section. 54.Fit bolt securing upper column to lower column universal joint and tighten to25 Nm (18 lbf.ft). 55.Fit air inlet pipe between turbo and inlet air filter and secure with clips.
60 - FRONT SUSPENSION CONTENTS Page DESCRIPTION AND OPERATION FRONT SUSPENSION - FROM 02MY 1................................................................ REPAIR PANHARD ROD - FROM 02MY 1........................................................................... BEARINGS - FRONT HUB 1...................................................................................
FRONT SUSPENSION 1 DESCRIPTION AND OPERATION FRONT SUSPENSION - FROM 02MY 1.Bolts 2.Bushes 3.Panhard rod Changes have been incorporated to improve the durability of the suspension. The current Panhard rods are forged. New Panhard rods are introduced which are fabricated from tubular steel and are handed. The rods are fitted with larger bushes which use M16 bolts in place of the M14 bolts. The torque for the new bolts is raised to 230 Nm (170 lbf.ft). The Panhard rod support brackets are now fabricated from upgraded steel which allows the higher torque figure to be applied to the fixing bolts.