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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual
Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual
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54FRONT AXLE AND FINAL DRIVE 6 OVERHAUL 38.Place retaining plate, joint washer and oil seal over axle flange ready for assembly. 39.Fit swivel bearing housing to axle flange with 7 bolts. Tighten to73 Nm (54 lbf/ft). 40.Grease and fit upper and lower swivel pin taper roller bearings. 41.Position swivel pin housing over swivel bearing housing. 42.Coat joint washer both sides with sealing compound and position on lower swivel pin. 43.Loosely fit brake shield bracket plus lower swivel pin with lug outboard to swivel pin housing. 44.Loosely fit top swivel pin plus existing shims and brake hose bracket to swivel pin housing. 45.Apply Loctite 270 or equivalent to lower swivel pin bolts.25 Nm (18 lbf/ft),bend over lock tabs. 46.Tighten top swivel pin bolts to65 Nm (48 lbf/ft). Check and adjust preload on bearings NOTE: Swivel housing oil seal and axle should not be fitted. 47.Attach a spring balance to track rod ball joint bore and pull balance to determine effort required to turn swivel pin housing. Resistance, once initial inertia has been overcome, should be1.16 to 1.46 kg.Adjust by removing or adding shims to top swivel pin. 48.When setting is correct remove top swivel bolts, apply Loctite 270 or equivalent. Refit bolts and tighten to65 Nm (48 lbf/ft),and bend over lock tabs. 49.Apply recommended grease between lips of swivel oil seal.50.Fit oil seal, joint washer and retaining plate with 7 bolts and spring washers. Tighten to11 Nm (8 lbf/ft). 51.Fit tie rod and drag link and secure with new cotter pins. Tighten fixing to40 Nm (30 lbf/ft). 52.Fit brake disc shield. 53.Loosely fit lock stop bolt and nut. 54.Apply a recommended grease between lips of swivel housing oil seal. 55.Secure oil seal with retaining plate and securing bolts. Tighten to11 Nm (8 lbf/ft). 56.Fit track-rod and drag link and secure with new cotter pins. 57.Loosely fit lock stop bolt for later adjustment. 58.Fit brake disc shield. Fit driveshaft and stub axle 59.Insert axle shaft, and when differential splines are engaged, push assembly in fully. CAUTION: Take care not to damage axle shaft oil seals. 60.Place a new joint washer in position on swivelpin housing to stub axle mating face. Coat threads of stub axle bolts with Loctite 270. 61.Fit stub axle with flat at 12 O’clock position. CAUTION: Ensure that constant velocity joint bearing journal is butted against thrust ring on stub axle before stub axle is secured. 62.Place mud shield in position and secure stub axle to swivel pin housing with 6 bolts and tighten evenly to65 Nm (48 lbf/ft). 63.Fit brake jump hoses to brake jump hose bracket. 64.Fit complete front hub assemblySee FRONT SUSPENSION, Repair. Front hub bearings. 65.Check swivel pin housing oil drain plug is fitted. 66.Fill swivel assembly to correct level, with new oil See MAINTENANCE , Under vehicle maintenance. NOTE: On later vehicles fill swivel pin housing with 0.33 Litres of Molytex EP 00 grease. 67.Set steering lock stop boltsSee STEERING, Adjustment. Steering lock stops.
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.