Land Rover Defender 90 110 Workshop 1984 Rover Manual

							STEERING 
/- .: ,,;...-, .: . .. _.. Sector shaft cover assembly ,..& . ..__., ....,_ . ,..,. =: ... i..Y., ..? 
31. The cover,  bush and seat  are supplied  as a U.. 
complete  assembly for replacement purposes. 
L 
57 
Sector shaft adjuster  locknut 
32. The locknut  functions also  as a fluid seal  and must 
be  replaced  at  overhaul. 
Valve  and worm assembly 
33.  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. 
*- .. . .. . .. . .. I. 
RR931M 
34. Remove  the damaged  rings ensuring  that no 
damage  is done  to the  seal  grooves. 
35. 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: The  expander  will not  pass  over  rings 
already  fitted. These  rings must be  discarded  to 
allow access  then renewed. 
36. Examine the bearing  areas for wear. The areas 
must  be smooth  and not indented.  37.  Examine 
the worm  track which  must be smooth 
and  not indented. 
38. Check for wear  on the  torsion  bar assembly  pins; 
no  free  movement  should 
cxist between the input 
shaft and  the worm. 
NOTE: Any sign of wear  makes  it essential  that the 
complete  valve and worm  assembly 
is renewed. 
Ball bearing  and cage assemblies 
39. Examine  the ball  races  and  cups  for  wear  and 
40.  If the  ball  cage  has worn  against the bearing  cup, 
fit 
general condition. 
replacements. 
41.  Bearing  balls must  be 
retained by the cage. 
42. Bearings  and  cage repair  are  carried out by the 
complete  replacement 
of the bearings  and cage 
assembly. 
43. To remove  the inner  bearing  cup  and  shim 
washers,  jar the steering  box 
on the work  bench, or 
use a suitable  extractor. 
NOTE: Should dificulty 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. 
continued 
36 
23  
						

							571 STEERING 
Rack thrust  pad and adjuster 
44. Examine the thrust pad for  scores. 
45.  Examine the  adjuster for wear  in the  pad  seat. 
46. Examine the nylon  pad for distortion and  adjuster 
grub  screw  assembly  for wear. 
46 
I 
I 
45 
I 
I 
44 
 
A 
1 W RR934M 
Rack and piston 
47. Examine for excessive  wear on the rack  teeth. 
48.  Ensure  the thrust  pad  bearing  surface is free  of 
scores and  wear. 
R 
Input shaft needle bearing 
52. 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. 
RR936M 
Reassemble 
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 
53. Fit  the  seal,  lipped  side first,  into  the housing. 
When  correctly  seated, the seal  backing  will lie flat 
on the bore  shoulder. 
54. Fit the extrusion  washer and secure  with the circlip. 
RR935M 
49. Ensure  that the piston  outer diameters  are free 
from  burrs and  damage. 
50. Examine  the  seal and ring  groove  for  scores  and 
damage. 
51. 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. 
24  
						

							STEERING 
Sector shaft seal 
57 
55. Fit the oil seal,  lipped  side first. 
56. 
Fit the extrustion  washer. 
57. 
Fit the  dirt  seal,  lipped  side last. 
58. Fit the circlip. 
Fitting the valve and worm assembly 
59. 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. 
, ...__ :>., .. ,.. 
						

							571 STEERING 
Fitting the rack  and piston 
68. Screw  a suitable  bolt into the piston  head for  use as 
an  assembly  tool. 
6 
. 
RR941M I J 
69. 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. 
70. 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. 
Fitting  the rack  adjuster 
71. Fit the sealing ring  to the  rack  adjuster. 
72.  Fit the  rack  adjuster and  thrust pad to engage  the 
rack.  Back off a half 
nylon turn on the adjuster. 
73.  Loosely 
fit the nylon pad  and adjuster grub  screw 
assembly  to engage  the rack  adjuster. 
Fitting  the sector  shaft cover 
74. Fit the  sealing ring to the cover. 
75.  Screw  the cover  assembly  fully 
on to the  sector 
shaft adjuster  screw. 
----- - 
76.  Position the cover on to the  casing. 
77. Tap  home  the cover. If necessary  back  off on the 
sector  shaft 
adjustcr screw to allow thc cover to 
joint  fully with the casing. 
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. 
78. Fit  the  cover fixings  and tighten  to the  correct 
torque. 
Fitting  the cylinder  cover 
79. Fit the square section  seal to thc cover. 
80. Remove the  slave bolt and  press the  cover into the “j-;. 
cylinder  just sufficient to clear  the  retainer ring 
groove. 
P: 
RR942M 
26  
						

							STEERING 1571 
:-, ,. ,.Gz.::. ._,._ .* ,..z..y 
81. Fit the  retainer  ring to the groove  with one end of 
the  ring  positioned  12 
mm (0.5 in)  approximately 
from the extractor  hole. 
.. ./.>, . _. .... 
Adjusting  the sector  shaft 
82. Set the  worm on centre  by rotating  the input  shaft 
half  the total  number 
of turns from either  lock. 
RR945M 
83. Rotate  the sector  shaft  adjusting  screw  anti- 
clockwise  to  obtain backlash  between the input 
shaft  and the sector shaft. 
84.  Rotate  the  sector  shaft  adjusting screw clockwise 
until  the backlash  is just  eliminated. 
85.  Measure  and record  the  maximum  rolling 
resistance  at the  input shaft,  using a spring balance, 
cord  and torque 
tool R01016. 
86. Hold  still the  sector  shaft adjuster  screw  and 
loosely fit a new locknut. 
87.  Turn  in the  sector  shaft  adjuster  screw  until the 
figure  recorded 
in instruction 88 is increased  by 0,9 
to 1,3 kg (2 to 3 Ib) with the locknut tightened. 
Adjusting  the rack  adjuster 
88. Turn  in the  rack  adjuster to increase  the figure 
recorded  in 
90 by 0,9 to 1,3 kg (2 to 3 Ib). The  final 
figure 
may be  less  than  but must  not exceed 7,25 kg 
(16 Ib). 
89. Lock  the rack  adjuster in position  with the grub 
screw. 
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 Y2 turns approximately 
position. .. .. . .. . from full lock)  and equally  disposed  about the centre  The 
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 replace. 
NOTE: During the following  ‘Procedure’,  the stated 
positioning  and direction 
of the input  shaft applies  for 
both  LH and 
RH boxes.  However,  the procedures for 
shim  adjustment  where necessary,  differs between  LH 
and 
RH steering  boxes and is described  under the 
applicable  LH stg.  and 
RH stg. headings. 
Procedure 
90. With  the input  coupling shaft toward  the operator, 
turn  the shaft  fully anti
-clockwise. 
91. Check  the  torque  figures obtained  from lock-to- 
lock using  a  spring  balance  cord  and  torque tool 
R01016. 
w RR946M 
Adjustments 
92. Note  where  the  greatest  figures are recorded 
relative  to the  steering  position.  If the  greatest 
figures  are not recorded  across the centre of travel 
(i.e. steering  straight-ahead  position),  adjust  as 
follows: 
LH  steering  models. If the torque  peak occurs 
before the  centre  position,  add  to the  shim 
washer  value; 
if the torque  peak occurs after 
the  centre  position, subtract from the shim 
washer value. 
RH steering  models. If the  torque  peak  occurs 
before the centre  position,  subtract  from the 
shim  washer  value; 
if the torque  occurs after 
the  centre  position, add to the  shim  washer 
value. 
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). 
NOTE: Adjustment  of 0’07 mm (0.003 in) to the shim 
value  will move  the torque  peak area by 
‘/4 turn 
approximately  on the  shaft. 
27  
						

							57 
NOTE: Do not  maintain  this pressure for more  than 
30 seconds  in any  one minute to avoid  overheating 
the 
fluid and possibly damaging  the seals. 
STEERING 
97.  Road  test the vehicle. 
KEY TO ADWEST LIGHTWEIGHT POWER STEERING BOX 
1. Housing. 
2. Housing  bushes. 
3.  Seal. 
4.  Back
-up washer. 
5. Back-up seal. 
6.  Circlip. 
7. Seal. 
8. Drop-arm. 
9.  Tab  washer. 
10. Sector  shaft nut. 
11. Sector  shaft and follower  assembly. 
12.  Seal. 
13.  Bush. 
14.  Cover  plate. 
15.  Self  locking  screws
-4 off. 
16.  Bleed  screw. 
17.  Locknut. 
18. Rotor  seal. 
19.  Seal  washer. 
20. Circlip. 
21. Shims. 
22.  Bearing  track. 
23.  Bearing  case and balls.  24. 
Circlip. 
25.  Seal  torsion  bar. 
26.  Rotor. 
27.  Teflon  rings 
- 3 off. 
28. Stop-off  rings. 
29.  Worm. 
30. Bearing  cage and balls. 
31. Bearing  track. 
32.  Seal. 
33.  Worm  adjusting  screw. 
34. Locknut. 
35.  Piston. 
36. Piston ‘0’ ring. 
37.  Piston  Teflon  seal. 
38.  Cylinder  cover seal. 
39.  Cylinder  cover. 
40.  Cylinder  cover retainer. 
41.  Screw. 
42.  Rack  adjusting  screw. 
43.  Rack  adjusting  screw seal. 
44. 
Rackpad. 
45.  Fluid  line. 
28  
						

							.. .. . .. ... . .. . .I .. . .. 
I- 
T 
29  
						

							171 STEERING 
POWER STEERING  SYSTEM - Adwest Lightweight 
box 
Bleed 
1. Fill thc steering  fluid reservoir  to the  mark  on the 
side 
of the  reservoir  with  one of the recommended 
fluids. 
2. Start  and run the engine  until it attains  normal 
operating  temperature. 
3. Check and correct  the reservoir  fluid level. 
NOTE: During  the carrying  out of items 4, 5 and 6, 
ensure that the steering  reservoir is kept full. Do not 
increase  the engine  speed 
or move the steering  wheel. 
4. Run the engine  at  idle speed,  slacken  the bleed 
screw.  When  fluid seepage  past the bleed  screw  is 
observed,  retightcn the screw. 
ST1805M \\ --I/ v 
5. Ensure that  the  fluid level  is  in alignment  with the 
6. Wipe  off all fluid released during  bleeding. 
7. Check all hose  joints,  pump and steering box for 
fluid  leaks  under  pressure  by holding  the  steering 
hard  on 
full lock in both  directions. 
mark 
on 
thc reservoir dipstick. 
CAUTION: Do not maintain  this pressure for more 
than 
30 seconds  in any one minute, to avoid causing 
the oil to overheat  and possible  damage to the  seals. 
The  steering  should 
be smooth lock-to-lock in both 
directions,  that is, 
no heavy  or light  spots  when 
changing  direction when the vehicle 
is stationary. 
8. Carry  ut a short 
road test. If necessary,  repeat the 
30 
complete  foregoing  procedure. 
POWER STEERING SYSTEM - Adwest Lightweight 
box 
Test 
If  there  is a lack of powcr assistance  for the steering  the 
pressure  of the  hydraulic  pump should be checked  first 
before  rcncwing  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 uscd for testing 
the  power steering  system. This gauge 
is calibrated 
to  read  up  to 140 
kgf/cm2 (2000 Ibf/in2) and  the 
normal  pressure  which may be  expected 
in the 
power  steering  system is 
77 kgf/cm2 (1100 Ibf/in2). 
2. Under  certain  fault  conditions of the hydraulic F:h 
pump it is possible  to  obtain  pressures up to g ;,::; 
105 kgf/cm2 (1500 Ibf/in). 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 replcnish, thc 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 nccessary. 
6. Assemble  the test  equipment  and fit to the vehicle 
as  illustrated. 
7. Open  the tap in the  adaptor. 
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 
should  be 
70 to 77 kgf/cm2 (1000 to 
1100 Ibf/in2). 
(b) With  the  engine  idling and the steering  wheel 
held  hard 
on full  lock,  the pressure  should be 
28 kgf/cm2 (400 Ibf/in2) minimum. 
-4 
p: &. *,;:: .s 
Thesc checks  should  be carried  out first on one  lock, 
then 
on the other. 
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. 
10. Release  the steering  wheel and allow  the engine to 
idle.  The pressure  should be below 7 kgf/cm 
(100 Ibf/in2).  
						

							.. . 
STEERING 157 
11. If the  pressures  recorded during the  foregoing test 
are  outside  the specified  range, 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. 
ADJUST  POWER STEERING BOX - Adwest 
Lightweight  box 
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 
93 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. 
TEST  EQUIPMENT 
STl854M 
A. Steering  box 
B. Steering pump 
C. Existing hose  from steering  box 
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 
wheel  chocks. 
6. Road test the vehicle. 
.. ... . I. .... . .,. . l:: ::,.,. .. 
31  
						

							STEERING 
GEMMER POWER STEERING BOX OVERHAUL 
Special  tools: 
Drop  arm puller 
MS 252 A 
End cover  wrench  adaptor LST123 
Input shaft oil seal  installer LST124 
Sector  shaft oil seal  installer LST125 
Valve  seal installer  and valve  ring compressor LST126 
Preload  setting tool R01016 
Dismantle 
1. Remove  the steering  box from  the vehicle. 
2. Bend  back the  locking  tab and  remove  the drop 
arm  nut. Using  special 
tool MS 252 A or a suitable 
alternative,  withdraw the drop  arm from  the sector 
shaft. 
3. Using  special  adaptor  tool LST123 turn the 
cylinder cover  anti
-clockwise to expose end of the 
locking  ring. Now  turn the cover  clockwise  to 
extract  the ring. 
5. Slacken  the grub  screw  securing  the rack  pad 
adjuster. 
ST1811M ST1813M p *. 
4. To remove the cover, turn the  input shaft to the left 
lock for a LHD  drive  steering  box or to the  right 
for  a RHD  drive steering  box until  the rack  piston 
pushes  the cover  out to enable it to  be withdrawn 
by  hand. 
With a screwdriver remove the rack pad 
‘0’ ring  and spring. 
ST1815M f?; 
c_/ 
continued 
32