Land Rover Defender 90 110 Workshop 1984 Rover Manual

							STEERING I57 I 
r I . , ... REMOVE AND OVERHAUL  STEERING 8. Remove  the four screws  securing  the instrument 
panel  and pull  panel  away  from facia to enable  the 
COLUMN : I .,I, -_. .L * 
Remove the collapsible shaft speedometer  cable to be  disconnected. 
9. Also disconnect  two block conncctors. one 
1. Remove  the bonnet. 
2. Set  the  road  wheels  and  steering  wheel in the 
3. Mark  the relationship  of the  steering  column inner  multiplug 
connector  and one white  wire and 
withdraw  the panel  complete  with instruments. 
straight  ahead position. 
shaft 
to the top  universal  joint. 
4. 
NOTE: The Collapsible  shaft can be disconnected 
from  the steering  column only, if required,  by 
removing  the bolts  from  the top universal  joint and 
slackening  the top  bolt  of the  lower  universal  joint. 
Remove the  two bolts  from the  top universal  joint 
and 
the lower  bolt of the  bottom  universal  joint. 
Slacken  the top  bolt 
of the lower  universal  joint 
and  withdraw 
the shaft. 
Remove  the steering  wheel 
5. Remove  the  single  screw  retaining  steering wheel 
finisher and  remove the finisher. 
6. Remove the steering  wheel retaining nut and if 
necessary,  use a  suitable  puller to remove  the 
wheel. 
Remove  the instrument  panel 
7. Disconnect the battery. 
Remove the steering  column switches 
10. Remove  five screws  and two self-tapping  screws to 
remove the top half of the nacelle. 
11. Ease the bottom  half of the nacellc from the four 
switch  grommets  and disconnect  the mixture 
control cable  (Petrol vehicle)  and remove the 
lowcr 
nacelle. 
12. Disconnect  the four  multi-plugs,  one for each 
13. Remove  one clamp  screw on top of the  switch 
switch 
making  note 
of their positions. 
cluster  and withdraw 
the switches. 
continued 
3  
						

							STEERING 
Remove the steering  column lock-switch 
14. Note the position of the  wires  on the  back of the 
lock  switch  and disconnect  the lucars. 
15. Using  a  punch  or stud  extractor  remove the two 
shear  bolts securing  the switch  to the  column. 
Remove  the  switch and collect  the two  plain 
washers  between  the switch  and clamp. 
b 
ST572M 
Remove  the steering  column 
21. Remove  the bolt  securing  the tie-bar  to the  stecring 
column,  behind the instrument panel. 
Remove  the brake pedal box 
16. Remove  the  vent  cover  and the strip  retaining  the 
mill board trim covering  the brake  pedal 
mechanism  and remove  the  trim,  to  expose the 
pedal  box bolts. 
17. Remove the two  nuts  securing  the  brake  master 
cylinder 
to the servo and disconnect the vacuum 
hose  from  the servo. 
18. Remove  the six bolts  retaining  the pedal  box to the 
19. Disconnect  the wires  from the stop  lamp switch. 
20. Taking  care not to damage  the  brake  fluid pipes 
remove the pedal  box from the bulkhead  complete 
with  the brake  pedal assembly. 
bulk 
head. 
ST575M 
4 
22. Remove  the two  bolts  securing  the lower  end of the 
continued 
column.  
						

							STEERING ~ 
,: .I,_( . 23. 
Remove  the  two  bolts securing the two  halves  of 
the  top clamp  and the  two bolts  that secure the  top 
half  of the  clamp  to the  bulkhead  and  remove  the 
clamp  and rubber  packing. 
24. Remove  the  two bolts  securing  the column  inaia 
support  bracket 
to the bulkhead. 
25.  Remove 
the steering  column and main  support 
bracket from  the vehicle.  29. 
Drive  the needle  bearing  from the outer  column. 
C.  . *. I- 
ST576M t I 
Overhaul the steering  column 
26. Remove  the circlip  from the lower  end of the 
steering column. 
27. Drift out the inner  shaft  complete  with bearing 
from  the top  end 
of the column. 
28.  Remove  the  roll pin from  the  bearing  retaining 
collar  and  drive the collar  and bearing  from 
the 
inner shaft. 
ST577M 
shaft. 
31.  Fit  the  retaining  collar, ensuring  that 
it butts 
against  the bearing  and  that  the 
roll pin holes linc 
up. Secure  with the roll pin. 
32.  Fit a  new roller  bearing  to the  top end 
of the outer 
column 
to a  depth of 10 mm. 
33.  Fit  the inner  shaft and bearing  assembly  to the 
outer column and  secure with the circlip. 
continued 
ST579M 
5  
						

							Ei STEERING 
Fitting steering column 
34.  Fit the main  support  bracket  and  padding  to the 
steering  column and manoeuvre  the column  into 
position 
in the  vehicie. 
35.  Loosely  secure  the main  support  bracket and 
harness bracket to the  bulkhead  with two bolts. 
36.  Loosely 
fit the clamp and  rubber  packing strip to 
the column  and retain with two bolts. 
37.  Loosely  secure  the lower  end of the  column 
to the 
lower  support bracket  with two nuts and  bolts. 
38.  Loosely  secure the  clamp  bracket to the  main 
support  bracket with two bolts. 
-- 
41.  Fit the  pedal  box and secure  with the six bolts. Fit 
the  pedal  assembly  mill board  trim and secure  with 
retaining  strip, vent  cover and screws. 
42. 
Fit the  master  cylinder  to the servo and connect  the 
servo  vacuum  hose. 
43.  Connect the  stop lamp  switch 
leads. 
Fit steering  column lock switch 
44. Place  lock switch  in position  and rotate  the steering 
column  inner  shaft  to  line up the  slot  with the 
switch  plunger. 
continued 
39. 
Wn-bing inside  the vehicle  cab, fit the tie-bar to the 
cc 
40. Fir.. .ly tighten  the main  support  bracket  bolts, 
clamp  bracket  bolts,  upper clamp  bolts  and  the 
lower  support  bracket  nuts and bolts. 
n bracket and secure  with the single  bolt. 
6  
						

							* .. . , .. .. . .. . 
STEERING 
I. . 
57 
... ? . . .. . ... .. 
45. Secure  the lock  to the  column  with the clamp  and 
shear  bolts,  whilst  inserting  two plain  washers 
between  the switch  and clamp.  Tighten  the bolts 
but  not enough 
to shear  them.  Temporarily  fit the 
steering  wheel 
and operate the switch  and lock 
mechanism  several times to ensure  it functions 
properly  before finally tightening  the bolts  until the 
heads shear.  Connect  the electrical leads to the 
rear 
of the  switch. 
ST583M 
Fit steering column switch assembly 
46.  Fit the  steering  column switch assembly  and secure 
with  the single  screw.  Connect  the four  multi
-plugs 
to  the  main  harness. 
Fit instrument panel  and nacelle 
47. Offer  up the  instrument  panel and connect  the 
speedometer  cable, two block  connectors  one 
multi
-plug  and single  white wire. Secure  the panel 
with  the four  screws. 
7 
48. Locate  the top  half of the  nacelle  in position  and fit 
the  mixture  control cable (Petrol  only) to the  lower 
half.  Locate  the switch  grommets  and 
securc the 
two  halves  together  with the four  long  screws 
one 
short  and two self-tapping  screws. 
Fit the steering wheel 
49. Turn the cancelling  ring so that the slots  are 
vertical  and the lug with  the arrow  points  to the 
left,  in the  direction 
of the  indicator  switch. Engage 
the  steering  lock. 
50.  Fit the  steering  wheel with the finisher  attachment 
lug  at the  bottom.  Ensure that the indicator 
cancelling  forks locate  in the  cancelling  ring slots. 
Secure  the wheel  with the shake
-proof  washer  and 
nut  and  tighten 
to the correct  torque.  Fit the 
finisher and secure  with the single  screw. 
continued 
7  
						

							STEERING 
ST587 M 
Fit collapsible  steering shaft  POWER 
STEERING 
BOX OVERHAUL - Adwest e 
early vehicles 
Service  tools: 
C Spanner - 606600 
Peg Spanner - 606601 
Ring  expander 
- 606602 
Ring  compressor 
- 606603 
Seal  saver,  sector shaft 
- 606604 
Seal  saver,  valve and worm 
- R01015 
Torque  setting tool - R01016 
DISMANTLE 
1. Remove  the  steering box from  the  vehicle,  and 
51. 
52. 
If necessary,  fit new universal  joints to the support. 
Note that the 
long joint is fitted  to the short  length 
of shaft and short joint to the long  end.  The joints 
can  only  be fitted  one way  to the  shaft. 
With  the steering 
lock engagcd and the road  wheels 
in the straight  ahead position  line-up the  marks  withdraw 
the drop  arm. 
made 
in instruction 2 and fit the  collapsible  shaft  
assembly with the long  leg  of the  shaft  to  the 
steering  box. Fit 
the pinch  bolts  and tighten  to the 
correct  torque figure. 
ST 104 3 M 
2. Rotate  the  retainer  ring, as necessary, until one 
end  is approximately  12 
mm (0.500 in) from  the 
extractor  hole. 
3. Lift the cover retaining ring from  the groove  in the 
cylinder  bore, using a suitable  pointed drift applied 
through the hole provided  in the  cylinder  wall. 
4. Complete the  removal of the retainer  ring, using a 
screwdriver. 
5. Turn on left lock (L.H. steering)  until the piston 
pushes  out the end  cover  (for 
R.H. steering 
models,  turn 
on right lock). 
ST588M 
continued 
8  
						

							STEERING 
15. Tap the splined end of the spindle shaft  to free  the 
bearing. 
3 
57 
16.  Withdraw  the bearing  cup and caged  ball bearing 
17.  Withdraw  the valve  and worm assembly. 
18. 
Do not  disturb  the  trim  screw,  otherwise the 
calibration  will be adversely  affected. 
19. Withdraw  the inner  bearing  ball race  and shims. 
Retain  the shims. 
6. 
Slacken  the  grub screw  retaining  the rack  pad 
7. Remove  the rack  pad adjuster. 
8. Remove  the sector shaft  adjuster locknut. 9. Remove the sector shaft  cover fixings.  assembly. 
adjuster. 
10. Screw  in the  sector shaft adjuster  until the cover  is 
removed. 
11.  Slide  out the sector shaft. 
ST 10 4 5 M 
l6 R 17 
Steering box seals 
20. Remove  the circlip  and seals from  the scctor shaft 
housing  bore. 
NOTE:  Do not remove  the  sector  bush  unless 
replacement 
is required.  Refer to instruction 23. 
21. Remove  the circlip  and seals  from the input  shaft 
housing  bore. 
NOTE: Do not remove  the  input  shaft  needle 
bearing unless replacement 
is required. 
12. Withdraw  the  piston, using a  suitable UNC bolt 
13. Remove  the  worm  adjusting  screw locknut  using 
14. Remove  the worm  adjusting  screw  using  peg 
screwed 
into 
the tapped hole in the  piston. 
‘C’ spanner 606600. 
spanner 606601. continued 
.! .’ 
9  
						

							STEERING 
26 
ST1050M 
Sector shaft assembly 
27. Check that  there is no side play on the rollers. 
28.  If excessive  side play 
on the roller  does exist renew 
29. Check the  condition of the adjuster  screw threads. 
30.  Examine  the  bearing areas on the  shaft  for 
31. 
Examinc the  gear  teeth  for uneven or  excessive 
the 
sector shaft. 
excessive  wear. 
wear: 
Inspecting 
22. Discard all rubber seals  and provide  replacements. 
NOTE: A rubber seal is fitted behind  the plastic 
ring 
on the  rack  piston.  Discard  the seal  also  the 
plastic  ring and provide  replacements. 
22 
ST1049M 
STlOSl M  32 
Sector shaft cover  assembly 
32. The  cover,  bush and seat  are supplied  as a 
Steering  box casing 
23. If necessary,  replace  the  sector  shaft bush,  using c=mp!ete assemb!j! fe: :ep!ace!??en? pllrpnses. suitable  tubing as  a drift. 
wear.  replacement  is necessary  this can  be undertaken  by 
using  a suitable  tap. 
24. 
Examine  the piston  bore for traces  of scoring  and 
25. Examine  the inlet  tube  seat  for damage. If 33. The  locknut  functions also  as a fluid seal  and must 
sector shaft adjuster locknut 
e-.. be replaced  at overhaul. %:.:/ 
26. Examine  the feed  tube for signs  of cracking. 
10 
continued  
						

							STEERING 
::: ., ., 
.. . ,, .-. . .. .. . ... .- . __ . ... 
Valve and worm  assembly 
34. Examine  the valve  rings  which  must be free  from 
cuts, scratches  and grooves.  The valve rings  should 
be  a loose 
fit in the  valve  grooves. 
35. Remove  the  damaged  rings ensuring  that no 
damage 
is done  to the  seal grooves. 
36.  If required, 
fit replacement  rings, using the ring 
expander  606602. Both rings and  tool  may be 
warmed 
if found  necessary.  Use  hot  water  for this 
purpose.  Then insert  into  the  ring compressor 
606603  to cool. 
NOTE: Any  sign of wear  at locations 39,40 and 41 
make  it essential  that the complete  valve and worm 
assembly  are renewed. 
Ball  bearing  and cage 
assem blies 
42. Examine  the  ball races  and  cups  for wear  and 
43.  If the  ball  cage  has worn  against the bearing cup, 
fit 
44. Bearing  balls must  be retained  by the  cage. 
45.  Bearings  and cage  repair  are carried  out by the 
complete.  replacement  of the  bearings  and cage 
assembly.  The bearing  cup  may be replaced 
separately 
only. 
46. To remove the inner  bearing  cup and shim 
washers,  jar the steering  box on the work  bench. 
general condition. 
replacements. 
NOTE: The 
expander  will not pass  over  rings 
already  fitted. These rings must be discarded 
to 
allow  access  then renewed. 
NOTE: Should  difficulty  be experienced  at this 
stage,  warm the casing  and the bearing  assembly. 
Cool the bearing  cup using  a suitable  mandrel  and 
jar  the steering  box on the  bench. 
ST1052M 
37.  Examine the bearing  areas for  wear.  The areas 
must  be smooth and 
not indented. 
38.  Examine  the  worm track 
which  must be  smooth 
and  not indented. 
39. Check  for  excessive end-float between  the worm 
and  valve  sleeve.  End
-float must  not exceed 
0,12 mm (0.005 in). 
40.  Rotary  movement  between  the components at the 
trim  pin 
is permissible. 
41. Check  for  wear  on the  torsion  bar assembly  pins; 
no free  movement  should  exist between  the input 
shaft  and the worm. 
JI ST10 5 3 M 
45 
Rack  thrust  pad and  adjuster 
47. Examine the  thrust pad for scores. 
48.  Examine  the adjuster  for wear 
in the  pad  seat. 
49.  Examine  the nylon  pad and  adjuster  grub screw 
assembly for  wear. 
49 I 
continued 
40 
 
47 
  
						

							1571 STEERING 
Rack and piston 
50. Examine for  excessive wear on the rack  teeth. 
51. Ensure  the thrust  pad bearing  surface is free  of 
scores and  wear. 
52. Ensure that the piston outer diameters  are free 
from  burrs  and damage. 
53. Examine  the  seal and ring  groove  for scores  and 
damage. 
54. Fit a new  rubber  ring to the  piston. Warm  the white 
nylon seal  and fit this to  the piston.  Slide  the piston 
assembly  into the cylinder  with the rack  tube 
outwards.  Allow to cool. 
REASSEMBLE 
52 
NOTE: When  fitting  replacement  oil seals,  these  must 
be lubricated with  recommended fluid.  Also ensure  that 
absolute  cleanliness 
is observed during  assembly. 
Input shaft  oil seal 
56. Fit  the  seal,  lipped  side  first,  into the housing. 
When  correctly  seated, the  seal backing  will 
lie flat 
on  the  bore shoulder. 
57. Fit the extrusion washer  and secure  with the circlip. 
ST 10 58 M /I 
ST1056M 
Input  shaft needle bearing 
55. If necessary, replace  the bearing.  The replacement 
must  be fitted squarely 
in the  bore (numbered  face 
of the bearing  uppermost).  Then, carefully  push 
the  bearing  in until  it  is flush  with the  top 
of the 
housing  bore, Ideally,  the bearing  will be just  clear 
of the bottom  of the  housing  bore. 
Sector shaft seal 
58. Fit the  oil seal, lipped  side first. 
59. Fit the  extrusion washer. 
60. Fit the dirt  seal, lipped  side last. 
61. Fit the  circlip. 
continued 
55 / 
12