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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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FRONT SUSPENSION 1 REPAIR PANHARD ROD - FROM 02MY Service repair no - 60.10.07. Remove 1.Remove fixings at mounting arm. 2.Remove fixings at axle bracket. 3.Remove panhard rod. 4.Using a suitable length of steel tubing, press out flexible bushes. Ensure tubing locates on outer edge of bush and not on rubber inner. Refit 5.Fit replacement bushes. CAUTION: Apply pressure to outer edge of bush, and not rubber inner. 6.Fit panhard rod to axle bracket and mounting arm. Tighten fixings to230 Nm (170 lbf/ft).BEARINGS - FRONT HUB Service repair no - 60.25.14 Remove 1.Raise front of vehicle. WARNING: Support on safety stands. 2.Remove front road wheel. 3.Pull back front brake caliper jump hose shield and clamp brake hose. 4.Position container collect brake fluid. 5.Loosen brake pipe to jump hose union and disconnect. CAUTION: Use 2 spanners when loosening or tightening unions. 6.Remove 2 bolts securing brake caliper to hub. 7.Remove brake caliper. CAUTION: Plug the connections. 8.Remove dust cap. 9.Remove circlip and shim(s) from drive shaft. 10.Remove and discard 5 bolts securing driving member to hub. 11.Remove driving member and discard gasket.
60FRONT SUSPENSION 2 REPAIR 12.Knock back staking and using a suitable socket, remove and discard hub nut. 13.Remove washer from hub. 14.Remove hub and brake disc assembly complete with bearings. 15.Remove outer bearing and spacer from hub. 16.Remove grease seal and inner bearing from hub. 17.Remove inner and outer bearing tracks from hub. Refit 18.Clean hub and bearing locations. 19.Fit inner and outer bearing tracks to hub. 20.Pack inner bearing with grease and fit to hub. 21.Fit new seal flush with rear face of hub using LRT-54-003andLRT-99-003. 22.Clean stub axle. 23.Pack outer bearing with grease, fit spacer and bearing to hub. 24.PositionLRT-54-019over hub nut threads on axle casing. 25.Fit hub assembly to stub axle, remove LRT-54-019. 26.Fit washer and new hub nut and tighten to30 Nm (22 lbf.ft). 27.Rotate and push/pull hub to setle bearings. Tighten hub nut to210 Nm (150 lbf.ft). 28.To check drive shaft end float, mount a dial gauge using bracketLRT-99-503to driving member bolt hole. 29.Ensure dial gauge is contacting hub nut face. 30.Move drive shaft in and out noting dial gauge reading.31.If end float is present refer to table for correct spacer and change spacer as necessary. 32.When no end float is evident, remove the dial gauge and mounting bracket. 33.Stake the hub nut. 34.Clean hub and axle shaft faces. 35.Fit new driving member gasket. 36.Position driving member to hub and tighten new bolts to65 Nm (48 lbf.ft). 37.Fit original shim(s) to drive shaft and secure with circlip. 38.Position brake caliper to hub, align fixings, fit bolts and tighten to82 Nm (60 lbf.ft). 39.Remove plugs from brake pipe connections. 40.Connect brake pipe union to jump hose and tighten union. CAUTION: Use 2 spanners when tightening or loosening unions. 41.Remove brake hose clamp from jump hose. 42.Bleed brake system.See BRAKES, Adjustment. 43.Fit road wheel, remove axle stand and tighten wheel nuts to130 Nm (95 lbf.ft). 44.Operate foot brake to locate brake pads before taking vehicle on road.
FRONT SUSPENSION 3 REPAIR End Float (mm) Spacer size (mm)Colour code 0.00 15.5 Purple 0.025 15.4 Yellow 0.050 15.4 Yellow 0.075 15.4 Yellow 0.10 15.3 Red 0.125 15.3 Red 0.150 15.3 Red 0.175 15.2 Blue 0.200 15.2 Blue 0.225 15.2 Blue 0.250 15.2 Blue 0.275 15.1 Green 0.300 15.1 Green 0.325 15.1 Green 0.350 15.1 Green 0.375 15.0 Black 0.400 15.0 Black 0.425 15.0 Black 0.450 15.0 Black 0.475 14.9 White 0.500 14.9 White 0.525 14.9 White 0.550 14.9 White
64 - REAR SUSPENSION CONTENTS Page REPAIR BEARING - REAR HUB 1.......................................................................................
REAR SUSPENSION 1 REPAIR BEARING - REAR HUB Service repair no - 64.15.14 Remove 1.Raise rear of vehicle. WARNING: Support on safety stands. 2.Remove rear road wheel. 3.Remove 2 bolts securing brake caliper to hub. 4.Release caliper from disc and tie aside. 5.Remove 5 bolts securing axle shaft. 6.Remove axle shaft and discard gasket. 7.Knock back staking, and using a suitable socket, remove and discard stake nut. 8.Remove hub nut washer. 9.Remove hub and brake disc assembly complete with bearings. 10.Remove outer bearing and spacer from hub. 11.Remove grease seal and inner bearing from hub. 12.Remove inner and outer bearing tracks from hub. Refit 13.Clean hub and bearing locations. 14.Fit inner and outer bearing tracks to hub. 15.Pack inner bearing with grease and fit to hub. 16.Fit new grease seal flush with rear face of hub usingLRT-54-003andLRT-99-003. 17.Clean stub axle. 18.Pack outer bearing with grease, fit spacer and bearing to hub. 19.Fit hub assembly to stub axle, remove LRT-54-019. 20.Fit washer and new hub nut and tighten to30 Nm (22 lbf.ft). 21.Rotate and push/pull hub to settle bearings. Tighten hub nut to210 Nm (150 lbf.ft). 22.To check drive shaft end float, mount a dial gauge using bracketLRT-99-503to driving member bolt hole. 23.Ensure dial gauge is contacting hub nut face. 24.Move drive shaft in and out noting dial gauge reading.
64REAR SUSPENSION 2 REPAIR 25.If end float is present refer to table for correct spacer and change spacer as necessary. 26.When no end float is evident, remove the dial gauge and mounting bracket. 27.Stake the hub nut. 28.Clean hub and axle shaft faces. 29.Fit new driving member gasket. 30.Position driving member to hub and tighten new bolts to65 Nm (48 lbf.ft). 31.Fit original shim(s) to drive shaft and secure with circlip. 32.Position caliper to hub, fit bolts and tighten to82 Nm (61 lbf.ft). 33.Fit road wheel, remove axle stands and tighten road wheel nuts to130 Nm (96 lbf.ft). 34.Operate brake pedal to locate brake pads before driving vehicle. 35.Check and top up brake fluid.
REAR SUSPENSION 3 REPAIR End Float (mm) Spacer size (mm)Colour code 0.00 15.5 Purple 0.025 15.4 Yellow 0.050 15.4 Yellow 0.075 15.4 Yellow 0.10 15.3 Red 0.125 15.3 Red 0.150 15.3 Red 0.175 15.2 Blue 0.200 15.2 Blue 0.225 15.2 Blue 0.250 15.2 Blue 0.275 15.1 Green 0.300 15.1 Green 0.325 15.1 Green 0.350 15.1 Green 0.375 15.0 Black 0.400 15.0 Black 0.425 15.0 Black 0.450 15.0 Black 0.475 14.9 White 0.500 14.9 White 0.525 14.9 White 0.550 14.9 White