Land Rover Defender 90 110 Workshop 1984 Rover Manual

							STEERING 
Fitting the valve and worm assembly 
62. If removed,  refit the original  shim washer(s) and 
the inner  bearing  cap.  Only  vaseline  must be used 
as an  aid to assembling  the bearings. 
NOTE: If the  original shims are not available,  fit 
shim(s) of 0.76 mm (0.030 in) nominal thickness. 
63. Fit the inner  cage and bearings assembly. 
64.  Fit  the valve  and worm  assembly,  using  seal  saver 
R01015 to protect the input shaft seal. 
65. 
Fit the outer  cage and bearings  assembly. 
66. 
Fit the outer  bearing cup. 
SrlOSl M 
Fitting the  rack and piston 
71. Screw a  suitable  bolt into  the piston  head for use  as 
an assembly  tool. 
72.  Fit  the piston  and 
rack assembly so that the piston 
is  63.5 
mm (2.5  in) approximately  from the outer 
end 
of the  bore. 
73.  Feed  in the  sector  shaft using  seal saver  606604 
aligning 
the centre gear  pitch on the  rack  with the 
centre  gear tooth  on 
the sector  shaft.  Push in the 
sector shaft, and, at the  same  time rotate  the input 
shaft  about  a  small  arc to  allow  the sector  roller 
to 
engage the worm. 
continued 
67. Renew the  worm adjuster  sealing  ring  and loosely 
screw  the adjuster into the  casing. 
Fit the locknut, 
but  do not  tighten. 
68.  Turn  in the  worm  adjuster  until the end
-float  at the 
input  is almost  eliminated. 
69.  Measure  and  record the maximum  rolling distance 
of the valve  and  worm  assembly, using a spring 
balance  and cord  coiled  around the torque  setting 
tool 
R01016. 
70. I----- IUIII III .- the worm adjuster to increase  the figure 
recorded  in instruction  69 by 
1,8 to 2,2 kg (4 to 
5 Ib)  at 1.250  in (31.7 mm) radius  to settle the 
bearings, then  back 
off the worm  adjuster  until the 
figure  recorded  in instruction 69  is increased  by 
0,9 
to 1,3 kg (2 to 3 Ib)  only,  with the locknut  tight. 
Use  peg spanner  606601 and 
C spanner  606600. 
13  
						

							STEERING 
Fitting the rack  adjuster 
74. Fit the sealing ring  to the rack adjuster. 
75.  Fit the  rack  adjuster  and  thrust  pad 
to engage the 
76. Loosely fit the nylon  pad and  adjuster  grub screw 
Fitting  the cylinder  cover 
82. Fit the  square section seal  to the cover. 
83.  Remove  the slave  bolt and press  the cover  into the 
cylinder  just  sufficient to clear  the retainer  ring 
groove. 
84.  Fit  the  retainer  ring to the  groove  with one end 
of 
the ring  positioned  12 mm (0.5 in)  approximately 
from  the extractor  hole. 
rack. 
Back off a half  turn 
on the adjuster. 
assembly  to engage the  rack adjuster. 
76 75 
ST1063M 
Fitting  the sector  shaft cover 
77. Fit the  sealing ring to the cover. 
78.  Screw  the cover  assembly  fully on to the  sector 
79.  Position 
the cover on to the  casing. 
80.  Tap  home  the cover.  If necessary  back off 
on the 
sector  shaft  adjuster screw  to  allow the cover  to 
joint  fully with  the casing. 
shaft 
adjuster  screw. 
NOTE: 
Before  tightening  the fixings,  rotate the 
input  shaft about 
a small  arc to ensure  that the 
sector  roller 
is free to move in the  valve  worm. 
81. Fit the cover  fixings  and  torque  load to 2,2  to 2,8 
kgf 
m (16 to 20 Ibf  ft) (23  to 28 Nm). 
Adjusting  the sector  shaft 
85. Set the worm on centre  by rotating  the  input  shaft 
half  the total  number  of turns  from either  lock. 
86. Rotate  the sector  shaft  adjusting  screw anti- 
clockwise  to obtain  backlash  between the input 
shaft and the  sector shaft. 
87.  Rotate  the sector  shaft  adjusting  screw clockwise 
until  the backlash 
is just  eliminated. 
88.  Measure  and  record  the maximum  rolling 
resistance  at the  input  shaft, 
using a spring balance, 
cord and torque  tool 
R01016. 
89.  Hold still the  sector  shaft  adjuster  screw and 
loosely  fit a new  locknut. 
90. Turn in the  sector  shaft  adjuster  screw until the 
figure 
recordcd in instruction 88 is  increased  by 0,9 
to 1,3 kg (2 to 3 Ib) with the locknut  tightened. 
f. t. d 
continued 
ST1064M 
14  
						

							STEERING El 
e,t:i:t Adjusting the rack  adjuster 
91. Turn in the rack  adjuster  to increase  the figure 
recorded 
in 90 by 0,9 to 1,3 kg (2 to 3 lb).  The  final 
figure  may be less  than  but must  not exceed 
7,25 kg 
(16 Ib). 
92. 
Lock the  rack  adjuster  in position  with  the  grub 
screw.  Adjustments 
95. Note 
where  the  greatest  figures are recorded 
relative  to the  steering  gear position.  If the  greatest 
figures  are not recorded  across the centre 
of travel 
(i.e.  steering  straight ahead position),  adjust  as 
follows: 
L.H.  steering  models. If  the torque  peak occurs 
before  the centre  position,  add  to the  shim 
washer valve;  if the  torque  peak occurs  after 
the  centre  position,  subtract from 
the shim 
washer  valve. 
R.H.  steering  models. 
If the torque  peak  occurs 
before  the centre  position,  subtract  from  the 
shim  washer  valve; 
if the torque  occurs after 
the  centre  position,  add to the  shim  washer 
valve. 
Shim washers  are available  as follows: 
0,03 mm, 0,07 mm, 0,12 mm and 0,24 mm (0.0015 in, 
0.003 in, 0.005 in and 0.010 in). 
Torque 
peak check 
With  the input  shaft  rotated from lock
-to-lock,  the 
rolling  resistance  torque figures should  be greatest 
across  the centre  position 
(1% turns  approximately 
from  full lock)  and equally  disposed  about  the  centre 
position. 
This  condition  depends on the value 
of shimming  fitted 
between 
the valve  and worm  assembly  inner bearing 
cup  and the  casing. 
The original  shim washer  value will 
give  the correct  torque  peak  position unless major 
components have been replaced. 
NOTE:  During the following  Procedure,  the stated 
positioning  and direction 
of the input  shaft applies for 
both L.H. and R.H. boxes.  However,  the procedure  for 
shim  adjustment  where necessary,  differs between 
L.H. 
and R.H. steering  boxes and is described  under the 
applicable  L.H. stg. and  R.H.  stg. headings. 
- 
Procedure 
93.  With 
the input  coupling  shaft  toward the operator, 
turn 
the shaft  fully anti-clockwise. 
94.  Check  the torque  figures  obtained  from lock
-to- 
lock  using  a  spring balance  cord  and  torque tool 
R01016. 
NOTE: Adjustment of 0,07 mm (0.003 in) to the  shim 
value 
will move  the torque  peak area .by 9 turn 
approximately  on the  shaft. 
96.  Fit the  drop  arm to the  steering  box 
using a new tab 
washer.  Tighten  the nut  to  the  correct  torque and 
bend  over tab. 
97. Refit  the steering  box to the  vehicle. 
98. Replenish  the system  with  the  correct grade of 
fluid.  Refer  to  Recommended  Lubricants  and 
bleed  the system. 
99. Test  the system  for leaks,  with the engine running, 
by  holding  the steering  hard  on full  lock  in both 
directions. 
NOTE: 
Do not  maintain  this pressure  for more  than 
30 seconds  in any  one minute  to avoid  over-heating 
the  fluid 
and possibly  damaging  the seals. 
100. Road  test the vehicle. 
..  
						

							171 STEERING 
BLEEDING THE POWER  STEERING  SYSTEM 
TEST POWER  STEERING  SYSTEM 
Service  tools: 
Three
-way  adaptor - JD10-2/1 
Gauge - JDlO 
Hose - JD 10-3 
2-off Hose - JDIO-3A 
Adaptor 
- JD10-6/1 
Adaptor - JD10-6/2 
If  there  is a lack  of power assistance  for the steering  the 
pressure  of the  hydraulic  pump should  be checked  first 
before  renewing  any components 
of the  system.  The 
fault  diagnosis  chart  should  also  be used to assist  in 
tracing faults  in the  power  steering. 
PROCEDURE 
1. The hydraulic  pressure  test  gauge is used in 
conjunction  with the special  adaptor (as  illustrated) 
for  testing  the power  steering  system. This  gauge is 
calibrated  to read  up 
to 140 kgf/cm’ (2000 Ibf/in2) 
in the  power  steering  system is 60 kgf/cm2 
(850 Ibf/in2j. 
2. Under certain  fault  conditions of the hydraulic 
pump  it is  possible  to obtain  pressures  up 
to 
105 kgf/cm2 (1500 lbf/in2). Therefore,  it is 
important  to realise  that  the  pressure upon the 
gauge  is in  direct  proportion 
to the pressure  being 
exerted  upon  the  steering wheel.  When  testing, 
apply  pressure  to 
the steering wheel very gradually 
while  carefully  observing  the pressure gauge. 
3. Check,  and if necessary  replenish,  the  fluid 
reservoir. 
4. Examine  the power  steering  units and connections 
for  leaks.  All leaks  must  be rectified  before 
attempting  to test  the system. 
5. Check the steering  pump drive belt for condition 
and tension,  rectify as neccssary. 
The  pump  used 
on the V8 engined  vehicle is 
different  from  that fitted  to the  four  cylinder T-r 
engined vehicles  but the test  figures  are the  same 
for  both  pumps,  Diagrams  show  how 
the test 
equipment  is assembled  for both  vehicles. 
6. Assemble  the test  equipment  in accordance  with 
the  diagram  for the vehicle  concerned. 
7. Open the tap  in the  adaptor JD10-211. 
8. Bleed  the system  but  exercise  extreme  care  when 
carrying  out this  operation 
so as not to overload  the 
pressure gauge. 
9. With  the system  in good  condition,  the pressures 
should  be as 
follows: 
(a)  Steering  wheel held  hard on full lock  and 
engine  running  at 
1,000 rev/min, the pressure 
shouici be 60 to 67 i
						

							STEERING 
These checks  should  be carried  out first  on one  lock, 
then  on the  other. 
57 
CAUTION: Under  no circumstances  must  the  steering 
wheel  be  held on full  lock  for  more than 
30 seconds  in 
any  one  minute,  otherwise  there will  be  a  tendency 
For 
the oil to overheat  and possible damage  to the  seals  may 
result. 
LU 
ST915M 
110 and 90 Engine Diagram 
A Steering  box. 
B Steering  pump. 
C Existing hose, steering  box to pump. 
D Hose JD10-3A. 
E Test adaptor JD10-2. 
F Pressure  gauge HY23. 
G Hose JDIO-3A. 
H Thread adaptor JDlO-6. 
I Thread  adaptor JDlO-6. 
ST916M 
V8 Engine Diagram 
A Steering  box. 
B Steering pump. 
C Existing hose, steering  box to pump. 
D Hose JD10-3. 
E Test  adaptor JD10-2. 
F Pressure  gauge HY23. 
10. Release the steering  wheel  and  allow the engine  to 
idle.  The pressure  should be: 
7 kgfkm’ 
(100 Ibf/in2). 
11. If the  pressures  recorded during the foregoing  test 
are  outside  the specified 
rangc, or pressure 
imbalance 
is recorded,  a fault  exists in the system. 
To determine if the  fault  is in the steering  box or 
the pump,  close the adaptor  tap for a period not 
exceeding  five seconds. 
12. If the  gauge  fails to register  the specified  pressures, 
the  pump  is inefficient  and the pump  relief valve 
should  be examined  and renewed  as necessary. 
13.  Repeat  the foregoing  test after  renewing  the relief 
valve  and bleeding  the system.  If the  pump 
still 
fails  to achieve  the specified  pressures,  the pump 
should  be overhauled  or 
a new unit fitted. 
14. If pump  delivery is satisfactory  and low pressure  or 
marked  imbalance  exists, the fault  must  be 
in the 
steering  box valve  and worm  assembly. 
17  
						

							57 
AD JUST POWER STEERING BOX 
STEERING 
NOTE:  The condition of adjustment  which must be 
checked is one of minimum  backlash without 
overtightness  when the wheels  are in the  straight
-ahead 
position. 
1. Jack  up the front  of the  vehicle  until the wheels  are 
clear 
of the  ground. 
WARNING:  Wheels must be chocked  in all 
circumstances. 
2. Gently rock  the  steering  wheel about the  straight- 
ahead  position  to obtain  the ‘feel’ of the backlash 
present.  This  backlash must  not  be more  than 
9,5 mm (0.375  in). 
3. Continue  the  rocking  action  whilst an  assistant 
slowly  tightens  the steering  box adjuster  screw after 
slackening 
the locknut  until the rim  movement  is 
reduced  to 
9,5 mm (0.375 in) maximum. 
4. Tighten  the locknut,  then  turn  the  steering  wheel 
from  lock to lock  and check  that 
no excessive 
tightness  exists at any  point. 
5. Lower  the vehicle  to ground  level and  remove  the 
6. Road test the vehicle. 
wheel 
chocks. 
V8 ENGINE POWER STEERING PUMP 
OVERHAUL - Series 30 
Dismantle 
1. Remove the  steering pump from the vehicle. 
2. Clean  the exterior of the pump  and  drain off any 
oil. 
3. Remove the bolt,  spring  washer  and large  plain 
washer securing  the pulley  to the pump shaft. 
4. Using  a  suitable  puller, withdraw  the pulley. Do 
not  attempt  to hammer  the  shaft from the pulley, 
or  lever  the pulley  from the shaft, as  this may  cause 
internal  damage. 
5. Withdraw  the square  key from  the shaft. 
6. Remove the four  bolts and spring  washers  securing 
the  bearing  retainer plate  and front mounting plate 
to  the  pump  body. Remove the  plates. 
7.  Remove  the three  bolts and spring  washers 
securing  the rear  mounting  plate to the  pump body 
and  remove  the plate. 
8. Clamp the  pump body in a vice,  ensuring  that  the 
jaws  are protected. 
9. Remove  the union  bolt and withdraw  the fibre 
washer, inlet  adaptor and rubber  gasket. 
NOTE: The tubular  steel venturi flow director  under the 
inlet  adaptor 
is pressed  into the cover  and should  not be 
removed. 
10. Remove  the six Allen  screws securing  the cover to 
the  pump  body.  Separate  the cover  from the body 
vertically 
to prevent  the parts  falling  out. 
11. Remove  the pump from  the vice. 
continued 
18  
						

							STEERING 15711 
.. 12. Remove the ‘0’ ring  seals  from the grooves  in the 
13. Carefully  tilt the  pump  body,  and  remove  the six 
14.  Draw  the carrier  off 
the shaft, and remove  the drive 
15. Remove  the shaft  from the body. 
“ .- *I. 1 pump body. 
rollers. 
pin. c ”- 
5,42 
. ,., . . .. . .... 
15,28 
13fl 12,33 
// 
RR186M 14,30 
16. Remove  the cam  and the cam  lock  peg from  the 
pump  body. 
17.  If necessary  withdraw the sealed  bearing  from the 
shaft 
18. Remove the  shaft seal from  the body, ensuring that 
no damage is caused to the  shaft  bushing. 
19. Remove  the  valve cap, ‘0’ ring, valve  and valve 
spring  from the body.  Place all parts where 
they will 
not be damaged, or subject  to contamination. 
RR 187M 
NOTE: Ensure  that the aluminium  restrictor in the  output 
port is thoroughly  cleaned but not dislodged. 
Reassemble 
23. Carefully  examine a new  shaft  seal to ensure  that it is 
clean  and  undamaged.  Smear 
the sealing lips with 
grease and  apply a fine  smear  of ‘Wellseal’  to  the 
pump  body where 
the outside diamcter of the  oil seal 
locates  (applies  to metal cased seals).  Place the seal 
square  to the housing recess  with the lip towards the 
inside  of the  housing. 
24.  Press  the seal  into  position  approximately 
0.80 mm 
(& in) below the seal  housing face,  ensuring  that it 
does not tilt. 
25. Replace  the cam  lock  peg into the  location in the 
body. 
26. Renew the cam if worn  or damaged.  Refit the cam, 
ensuring that 
it seats  correctly in the body  and that 
the  slot  locates  over the locking  peg. 
27. Fit a new  sealed  bearing  onto the pump shaft. 
28. Insert  the shaft  and bearing  assembly  into the seal 
29. Refit the carrier  drive pin in the  shaft. 
30. Inspect the  carrier and replace in position,  ensuring 
that  the greater angle  on 
the carrier teeth is in the 
leading  position  as illustrated. 
side 
of the 
body. 
Y 
3 
RR183M 
Inspection 
20. Wash  all parts in a suitable solvent, air  dry, or wipe 
clean  with a lint
-free cloth if air  is not  available. 
21.  Check  the pump  body and cover  for wear.  Renew 
either  part, 
if faces or bushes  are worn. 
22.  Check 
the pump  shaft  around  the  drive  pin slot. 
Remove  any burrs. 
rollers. 
31. Inspect  the rollers,  paying particular attention to the 
finish  on  the  end. Renew  the rollers 
if scored, 
damage 
or oval.  Refit the  rollers to the carrier. 
32. Using  a straight  edge across  the cam  surface, and  a 
feeler  gauge,  check the end  clearance  of the  carrier 
and  rollers 
in the pump  body. If the end  clearance  is 
more  than 
0,05 mm (0.002 in) rencw the carrier  and 
19  
						

							STEERING 
32 
\\- 
6 a$ 
POWER STEERING BOX OVERHAUL - Lightweight 
Adwest 
Service  tools: 
‘C’ Spanner - LST120 
Worm adjusting  socket - LST119 
Drop arm extractor - MS252A 
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 arm from  the vehicle,  and 
withdraw  the drop arm. 
33.  Smear  a fine trace 
of Loctite  275 to the  pump  body in 
a ‘figure 
of 8’  outside the ‘0’ rings  and inside  the bolt 
holes.  Install new 
‘0’ rings to the  body  of the  pump. 
34.  Refit the  cover 
on the pump  body and secure  with six 
Allen  screws  and spring washers. 
35.  Tighten  the Allen  screws, 
in diagonal  sequence, 
checking  that the shaft  rotates  freely and does  not 
bind.  Final  torque 
to be 15 to 17 Ibf.ft (20 to 23  Nm). 
36.  Replace  the square  sectioned  rubber gasket 
to the 
groove  around  the inlet  port  and  replace the inlet 
adaptor,  fibre washer and  union bolt. Torque 
to 28 to 
30 
1bf.ft (38 to  41 Nm). 
secure  with three  bolts and spring  washers. 
retainer  plate 
to the pump  body and secure  with four 
bolts  and spring  washers. 
39.  Refit  the flow  control  valve spring  in the  bore.  The 
spring  tension  should be 
8 to 9 Ibf (11 to 12 Nm) at 
21 
mm (0.820  in). If not,  renew  the spring. 
40.  Replace  the valve  in the  bore,  inserting  the valve 
so 
37.  Refit  the rear mounting  plate to the pump  body and 
38.  Refit  the front  mounting  plate  and  the bearing 
RR923M 
43. 
44. 
f?“ tha; the exposed  ball end enters  last. Ensure that the 
valve is not  sticking. 
41.  Renew  the 
‘0’ ring on the valve cap and assemble  in 
the  pump.  Tighten  the cap to a torque  figure 
of 30 to 
35 
Ib.ft (40 to 47 Nm). 
2.  Rotate the  retainer ring, as  necessary, until one end 
is  approximately 
12 mm (0.500 in) from the extractor .er 
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. 
screwdriver. 
42. 
Refit  the pulley  key. ’ Refit the pulley to the shaft and with the 4. Complete the removal of the retainer ring, using a special  washer,  spring and  washer and bolt. Tighten 
the  bolt  to  a  torque figure 
of 10 to 12 Ibf.ft (13  to 5. Turn  on  left lock (LH steering)  until the piston ,L ’*TA_ 10 iumi. 
Refit  the steering  pump to the  vehicle.  pushes 
out the end  cover (for RH steering models, 
turn  on right 
lock). 
continued 
20  
						

							STEERING 
1 . ’. 
57 
5-K lll  
. RR1695M w 
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. 
adjuster. 
10. Screw 
in the sector  shaft adjuster  until the cover  is 
11.  Slide  out the sector  shaft. 
removed. 
1 
RR924M 
15. Tap 
the splined  end of the  spindle  shaft to free  the 
16.  Withdraw  the bearing  cup and 
cagcd ball  bearing 
bearing. 
assembly. 
l6 17  A 
17. Withdraw  the valve  and worm  assembly. 
18. Withdraw  the inner  bearing  ball race  and shims. 
Retain  the shims. 
continued 
12.  Withdraw  the  piston, using a suitable bolt  screwed 
13. Remove the worm  adjuster  locknut using ‘C’ 
14. Remove the worm  adjuster using socket LSTl19. 
into the tapped  hole in the  piston. 
spanner, 
LST120. 
‘I . 
. ; , 
21  
						

							157 I STEERING 
Steering box seals 
19. Remove  the circlip  and seals  from the sector  shaft Steering 
box casing 
22.  If necessary,  replace  the sector  shaft bush,  using 
23.  Examine  the piston  bore for traces 
of scoring  and 
housing 
bore. 
NOTE: Do not remove  the sector  bush unless  wear. 
replacement  is required.  Refer to instruction 
22. 
suitable  tubing as a drift. 
20. Remove the circlip  and  seals  from the input  shaft 
housing  bore. 
RR929M v/ 22 23 
24. Examine  the  inlet  tube seat for  damage.  If 
replacement  is necessary  this can be undertaken  by 
using  a suitable  tap. 
25. Examine the feed tube for signs of cracking. 
NOTE: Do not remove  the input  shaft needle 
bearing  unless replacement 
is required. Sectorshaftassembly 
26. Check  that there  is no  side play on  the rollers. 
27. If excessive  side play on the roller  does exist renew 
28. Check  the condition of the  adjuster  screw threads. 
29. Examine  the  bearing areas on the  shaft for 
30. Examine the gear teeth for uneven or excessive 
Inspecting 
21. Discard 
all rubber  seals and provide  replacements.  the 
sector  shaft. 
excessive  wear. 
wear. 
NOTE: A rubber  seal is fitted behind  the plastic 
ring  on the  rack 
Piston- Discard the sea1 also the 
plastic  ring and provide  replacements. 
RR928M 
22 
RR930M ‘3 2