Land Rover Defender 300tdi Workshop 3rd Edition Rover Manual
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57STEERING 8 OVERHAUL 84.Refit locknut and tighten. NOTE: It is important steering box is centralised before any adjustments are made. 85.Check maximum rolling torque one and a quarter turns either side of centre position, using a torque wrench and spline socketLRT-57-025. Rotate adjuster screw to obtain across centre torque of 0.34 Nm plus torque figure at one and a quarter turns. Tighten adjuster locknut to 60 Nm (44 lbf/ft). Adjusting rack adjuster. 86.Turn in rack adjuster to increase figure measured in instruction 85. by 0.23 - 0.34 Nm. The final figure may be less, but must not exceed 1.35 Nm. 87.Lock rack adjuster in position with grub screw. Tighten to 5 Nm (4 lbf/ft). Torque peak check With input shaft rotated from lock to lock, rolling torque figures should be greatest across centre position and equally disposed about centre position. The condition depends on value of shimming fitted between valve and worm assembly inner bearing cup and casing. The original shim washer value will give correct torque peak position unless major components have been replaced. Procedure 88.With input coupling shaft toward the operator, turn shaft fully counter-clockwise. 89.Check torque figures obtained from lock to lock using torque wrench and spline socket LRT-57-025. 90.Check also for equal engagement either side of centre.Adjustments 91.Note where greatest figures are recorded relative to steering position.If greatest figures are not recorded across centre of travel (steering straight-ahead), adjust as follows: If torque peak occursbeforecentre position,addto shim washer value; if torque peak occursaftercentre position,subtractfrom shim washer value, refer to fitting valve and worm assembly . Shim washers are available as follows: 0.03mm, 0.07mm, 0.12mm and 0.24mm. NOTE: Adjustment of 0.07mm to shim value will move torque peak area by 1/4 turn on the shaft. CAUTION: When reshimming valve and worm, extreme caution must be exercised to prevent seal damage during reassembly.
STEERING 9 OVERHAUL Input shaft oil seal 92.Fit seal, lip side first, into housing. Use seal saverLRT-57-016and seal installer LRT-57-026. Note that seal is fitted to a depth of 4.75 - 5.00 mm from face of box. 93.Secure seal with circlip. 94.Smear inner lip of dirt excluder with PTFE grease. Fit dirt excluder usingLRT-57-027. When fitted correctly outer shoulder of excluder is 4.00 - 4.50 mm from face of box, dimension X. 95.Remove drop arm. Smear inner lip of dirt excluder with PTFE grease and refit, ensuring outer lip is flush with casing. 96.With input shaft on centre, align assembly marks on drop arm and steering box. Fit drop arm to steering box using a new tab washer. Tighten to 176 Nm (130 lbf/ft),bend over tab. 97.Fit steering box See Repair, Power Steering Box .
STEERING 1 SPECIFICATIONS, TORQUE REV: 05/99 TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Ball joint nuts 40.............................................................................................. Clamp bolt nuts 9........................................................................................... Steering column bracket nuts 22.................................................................... Steering wheel nut 43..................................................................................... Tie bar to mounting nut 110............................................................................. Universal joint pinch bolt 25............................................................................ PAS box Adjuster locknut 60................................................................................. Drop arm nut 176.................................................................................... Sector shaft cover to steering box 75..................................................... Steering box to chassis 81..................................................................... Steering box fluid pipes 14mm thread 15............................................... Steering box fluid pipes 16mm thread 20............................................... Tie bar 81............................................................................................... PAS pump High pressure fluid pipe 20..................................................................... Power steering pump mounting 35......................................................... Pulley bolts, power steering pump 10.................................................... Hose clamp 3........................................................................................ Front mounting plate bolts 9.................................................................. PAS reservoir Hose clamp 3........................................................................................ * Torque values below are for all screws and bolts used except for those that are specified otherwise. METRIC Nm M5 6...................................................................................................... M6 9...................................................................................................... M8 25..................................................................................................... M10 45................................................................................................... M12 90................................................................................................... M14 105.................................................................................................. M16 180.................................................................................................. UNC / UNF 1/4 9...................................................................................................... 5/16 24................................................................................................... 3/8 39..................................................................................................... 7/16 78................................................................................................... 1/2 90..................................................................................................... 5/8 136....................................................................................................
FRONT SUSPENSION 1 DESCRIPTION AND OPERATION DESCRIPTION The front suspension design allows maximum wheel travel and axle articulation providing good ground clearance without loss of traction or directional stability. Long radius arms are fitted to the front axle and provide maximum axle articulation which is vital for off road performance. The radius arms are secured to fabricated mounting brackets welded to the front axle. Flexible rubber bushes are used on a stem end joint to secure the rear of the radius arms to mountings on the chassis cross member. A panhard rod, which ensures that the front axle remains centrally located, is fitted transversely and also uses ferrule rubber bush mountings at both axle and chassis locations.Two rubber bearing bushes, with retaining straps, secure the rear of the anti-roll bar to the chassis mountings, while bushed links support the front of the bar to the front axle. Conventional long travel coil springs and hydraulic shock absorbers are used to control body movement in all conditions. The shock absorbers are secured to fabricated towers which are bolted to the chassis. The upper and lower fixings use a single location stud with flexible rubber bushes, support washers and securing nuts. Retaining plates are used to secure the coil springs to the fabricated towers and axle mountings. Rubber bump stops are fitted underneath the chassis, adjacent to the front road springs, and prevent possible damage that could occur should there be excessive axle to chassis movement. Front suspension 1.Panhard rod 2.Radius arms 3.Coil springs 4.Shock absorber 5.Anti-roll bar
FRONT SUSPENSION 1 REPAIR SELF LOCKING NUTS WARNING: Where self locking nuts are removed, they must be replaced with new nuts of same specification. PANHARD ROD 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 to 88 Nm (65 lbf/ft). RADIUS ARM Service repair no - 60.10.16. Remove 1.Loosen road wheel retaining nuts. 2.Raise front of vehicle. Support chassis on stands and remove wheel. 3.Support front axle weight with jack. 4.Remove radius arm to chassis side member fixings. 5.Disconnect track rod at ball joint.
60FRONT SUSPENSION 2 REPAIRREV: 05/99 6.Remove fixings, radius arm to axle. 7.Lower radius arm front end to clear axle and remove from vehicle. 8.Using suitable length of steel tubing, press out flexible bushes. Refit 9.Press in replacement bushes. CAUTION: When pressing in new bushes press on outer edge of bush and not rubber inner. 10.Fit radius arm to axle mounting. 11.Fit track rod at ball joint. 12.Fit radius arm to chassis. Tighten bolts to 176 Nm (130 lbf/ft). 13.Fully tighten radius arm to axle fixings to197 Nm (145 lbf/ft). 14.Fit road wheel, remove chassis stands and jack. Tighten wheel nuts to correct torque: Alloy wheels - 130 Nm (96 lbf/ft) Steel wheels -100 Nm (80 lbf/ft) Heavy duty wheels -170 Nm (125 lbf/ft) FRONT SHOCK ABSORBER Service repair no - 60.30.02. Remove 1.Loosen road wheel retaining nuts. 2.Support chassis on stands and remove road wheel. 3.Support axle weight with jack. 4.Remove shock absorber lower fixing and withdraw cupwasher, rubber bush and seating washer. 5.Remove four shock absorber bracket fixings. 6.Withdraw shock absorber and bracket assembly. 7.Withdraw lower seating washer, rubber bush and cupwasher. 8.Remove fixings, shock absorber to mounting bracket. 9.Withdraw mounting bracket. 10.Lift off top seating washer, rubber bush and cupwasher.
FRONT SUSPENSION 3 REPAIR REV: 05/99 Refit 11.Assemble shock absorber components. 12.Position shock absorber, complete with bracket and secure with 4 fixings. 13.Secure shock absorber lower fixing. 14.Fit road wheel, remove chassis stands and jack. Tighten wheel nuts to correct torque: Alloy wheels - 130 Nm (96 lbf/ft) Steel wheels -100 Nm (80 lbf/ft) Heavy duty wheels -170 Nm (125 lbf/ft) FRONT ROAD SPRING Service repair no - 60.20.11. Remove 1.Remove front shock absorber See Front shock absorber . CAUTION: Avoid over stretching brake hoses. If necessary, loosen hose connector locknuts to allow hoses to follow axle. 2.Lower axle sufficient to free road spring. 3.Withdraw road spring. 4.Withdraw shock absorber bracket securing ring. Refit 5.Fit shock absorber bracket retaining ring. Retain in position with a nut. 6.Position road spring and raise axle. 7.Remove nut retaining securing ring. 8.Fit front shock absorber See Front shock absorber .
60FRONT SUSPENSION 4 REPAIR BUMP STOP Service repair no - 60.30.10. Remove 1.Remove fixings. 2.Remove bump stop. NOTE: A chassis undertray may be fitted on some vehicle derivatives to conform to legal requirements. When under chassis remove and refit procedures are required, it may be necessary to remove the undertray See CHASSIS AND BODY, Repair, Front undertray . Refit 3.Position bolts in slots in chassis brackets. 4.Fit bump stop, secure with washers and nuts.ANTI-ROLL BAR Service repair no - 60.10.01 Remove 1.Mark for reassembly position of rubber bushes on anti-roll bar. 2.Remove 4 nuts, bolts and washers securing both anti-roll bar bush straps to chassis mounting brackets. 3.Remove nuts, bolts, washers and rubber bushes securing anti-roll bar to both links 4.Remove anti-roll bar. Refit 5.Position bushes on anti-roll bar. Ensure split points towards axle on RH bush and away from axle on LH bush. 6.Fit anti-roll bar with two straps. To ensure correct fit angled sides of bar should point down. Loosely fit the bolts, washers and nyloc nuts. 7.Fit bolt, washers and rubber bushes. Using new nuts fit anti-roll bar to links and tighten to 68Nm (50 lbf/ft). 8.Tighten nuts securing straps to30Nm (22lbf/ft).
FRONT SUSPENSION 5 REPAIR ANTI-ROLL BAR LINKS Service repair no - 60.10.04. Remove 1.Remove 2 nuts, bolts, washers and rubber bushes from ball joint links. 2.Remove cotter pin and loosen castellated nut a few turns. 3.Release link joint using special tool18G 1063A as shown. 4.Remove castellated nut and link. Refit 5.Fit link and castellated nut. Ensure ball joint link arm points up. Tighten nut to 40 Nm (30 lbf/ft) and fit new cotter pin. 6.Align anti-roll bar to links. 7.Fit bolts, washers and rubber bushes using new self locking nuts and secure anti-roll bar to links. Tighten fixings to 68 Nm (50 lbf/ft).
FRONT SUSPENSION 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are tightened to the correct torque. Nm Anti-roll bar - Strap nyloc nuts 30.............................................................................. - Ball link self lock nut 68........................................................................ - Castellated nut 40................................................................................ Drag link to axle 40......................................................................................... Securing ring for mounting turret 14............................................................... Radius arm to chassis 176............................................................................... Panhard rod mounting arm to chassis 88....................................................... Panhard rod to axle 88.................................................................................... Panhard rod to mounting bracket 88............................................................... Tie bar to Panhard rod 110.............................................................................. Radius arm to axle 197....................................................................................