Land Rover Defender 90 110 Workshop 1984 Rover Manual

							*.-> ,.. ,,.. ... .* c.;i:,.,] ,. . ... .. - ... . ..,.:e 
STEERING 157 
7. Restrain  the  sector shaft adjuster  with a 6 mm 
8. Remove  the six bolts  securing  the  sector shaft 
hexagonal 
key and remove  the locknut. 
cover. 
ST1816M 
9. Hold the  sector  shaft cover  and turn  the adjuster 
and  screw  clockwise  until 
the cover can be 
removed. 
10. Lift-out the  sector shaft. 
. ,.I.. . .. . 
ST 
11. Remove the  rack and piston  assembly  and collect 
the  rack  adjuster thrust  pad. 
ST 1819M 
12. Drive-out the worm  adjusting  screw locking  pin. 
13. Using  special tool LST123, remove the input  shaft 
worm  adjusting  screw anti
-clockwise. 
14. Tap the spiined end of the  input  shaft  to  free the 
outer  bearing.  Remove  the bearing  track and ball 
cage assembly. 
33  
						

							57 
15. Withdraw the  input  shaft,  worm and valve 
assembly. 
STEERING 
15 
ST1822M 
16. Release  the circlip  and remove  the  steel  washer 
17. Remove the wire  circlip, anti-extrusion  washer and 
and 
oil seal from 
the sector  shaft housing. 
Qil seal from the input  shaft housing. 
Sector  shaft assembly 
5. Check  that no side  play  or wear  exists  in the roller. 
6. Check  the condition  of the  adjuster and  its retainer 
7. The  axial  clearance of the adjuster  should not 
8. Examine  the bearing  journals on the shaft for  wear 
9. Check  the gear teeth  for  excessive and uneven 
and that 
the crimping 
is sound. 
exceed 
0,20 mm (0.008 in). 
and  damage. 
wear,  scores  and pitting. 
continued 
ST1949M I I 
INSPECTION AND OVERHAUL OF COMPONENTS 
Steering  box housing 
1. Examine  the sector  shaft  upper  and lower needle 
roller bearings  and 
if necessary drive them from the 
housing with  a suitable  drift. 
2. Inspect the  input  shaft  needle bearing  and if worn 
drive  it from  the housing  and press-in  a 
replacement. 
3. Examine  the piston  bore for wear and scores. 
4. Check  the input shaft  bores for wear and scores. 
ST1954M 
34  
						

							STEERING 157 I 
Valve and worm  assembly 
NOTE: If the  inner  ball race  is faulty  and unfit for 
further  service it cannot  be renewed  and a new  valve 
and  worm  assembly  must be obtained  and fitted.  Should 
this  be the  case,  the following  checks of the  valve  and 
worm  can be  ignored. 
10. Examine  the  valve  rings  which  must be free  from 
cuts,  scratches  and scores. 
Also, the rings  should 
be  a loose  fit 
in the grooves. 
11. If  any  ring  is unsatisfactory,  all the  rings  must be 
renewed.  When removing 
the rings take care  not to 
damage the  valve grooves. 
12. To fit new  rings  use  special  tool LST126, which 
consists 
of the  following  three parts:- 
a) Ring  expander. 
b)  Split 
collcr. 
c) Ring  compressor. 
Before  using the tool 
lubricatc each  part with  the 
recommended power  steering fluid. 
13. Warm the five  rings  in hol water  leaving  them in 
the  water  until ready  for fitting.  When pliable, feed 
the  ring  for  the 
Iowcr groove  (nearest  the roller 
bearing)  over 
thc expander  and  position the 
expander  over 
the input  shaft,  slide thc ring into 
the  groove  and mould 
it into  position  with the 
fingers. 
13 
A 
ST1941 M 
14. Encircle the ring  with  the split  coller  and squeeze 
the  coller  together,  by hand,  and hold  for 
approximately thirty seconds. 
15. Remove  the split  coller  and  with care,  ease  the 
compressor  tool over 
the ring  and leave  for a fcw 
minutes to cool  before  carefully rcmoving the tool. 
ST1942M 
5 
16. Using  the  expander  tool, as  before,  fit  the 
remaining  four rings,  one at a time,  into  the 
grooves  and mould  with the fingers.  It is important 
that 
only one  ring  at a time  is placed on the 
expander  since in the  meantime  the  remaining 
rings  could  cool in an  expanded  condition making 
it 
difficult to locate and contract thc rings in thc valve 
grooves.  Encircle the 
four rings with  the split coller 
and  squeeze  together 
for approximately  thirty 
seconds.  Then, with care,  ease the compression 
tool over  the four  rings  and allow  to cool  for about 
five  minutes  before carefully  withdrawing  the 
compressor. 
continued 
.- ._ .. .. _..‘ . .. 6.; .; .. . 
35  
						

							1571 STEERING 
17. Examine the bearing  surfaces of the valve  assembly 
for  wear  and scores. 
18. Examine  the worm track for  wear and pitting. 
19. Check  that  the  end-float between  the locator  and 
valve  sleeve  does not exceed 
0,12 mm (0.005 in). 
20.  Rotary  movement  between  the  components at the 
trim  pin 
is permissible. 
21. Check  that no free movement  exists on the  torsion 
bar  assembly  pin between 
the input  shaft and 
worm. 
29. Remove  the plastic  seal and the ‘0’ ring  seal 
30. Ensure that  the outer diameters  of the  piston  are 
31. Fit a new ‘0’ ring seal to the  piston groove. 
beneath 
it, from  the piston groove. 
free from  burrs  and damage. 
R0 
17 I 
ST1957M 18 20 19 
ST1955M 
22. The  valve  and worm  assembly should  be renewed if 
there  is wear  at the  following points: 
a)  Inner  and outer  bearing  tracks. 
b)  Worm. 
c) Valve  locator. 
d)  Input  shaft needle  bearing  Journal. 
23.  Examine  the outer  ball race and track  for wear  and 
general  condition.  The race  should  be renewed 
if 
there  is wear  and pitting  or if a new valve  and worm 
assembly 
is being  fitted. 
Thrust  pad and adjuster 
24. Examine the  thrust pad for scores. 
25. Check  that the thrust  pad seat  in the  adjuster  is not 
26.  Check  that the thrust  pad spring  is not  broken. 
worn 
or scored. 
Rack  and piston 
27. Examine the  rack teeth  for wear and  pitting. 
28. Check that the surface  on which  the thrust  pad 
bears  is not 
worn and  scored. 
32. To fit a new  plastic  seal to the  piston, warm  the seal 
in  hot  water  and 
fit to the  piston groove.  Insert  the 
piston  in the inverted  position 
i.e. piston  first into 
the  cylinder  and leave 
to cool. 
Sector  shaft cover 
33. Examine the sector  shaft cover needle  bearing  and 
if necessary extract the bearing  taking care not to 
damage  the housing. 
continued 
36  
						

							STEERING 
34. Drive-in a new  bearing, up to the  shoulder,  with 
the  bearing  number  and  chamfered ends of the 
rollers trailing. 
35. Fit a  new ‘0’ ring seal to the cover. 
36. Check  that  the  cover  bearing  lubrication  passage 
and  bleed  nipple 
hole is clear. 
57 
. :.I..: .. . ... ... .. , 
ST 1 
2. Fit the  sector shaft  upper needle  bearings, number 
outwards, up  to the  shoulder. 
ST 
Fitting the valve  and worm assembly (input shaft) 
3. Fit the  input  shaft to the  steering  box housing  and 
lubricate  with the recommended  fluid. Turn the 
shaft  to the  straight  ahead position. 
Assemble 3 
During  the  following assembly  instructions  absolute 
cleanliness  must  be observed. 
Also when  fitting 
components  and 
oil seals they must only be lubricated 
with  the recommended  fluid,  or petroleum  jelly. 
1. If removed,  fit the  sector  shaft  lower  needle 
bearings,  numbers outwards,  to the steering  box 
to 
just below  the chamfer. 
ST1933M 
4. Fit the input shaft outer  bearing  and track. 
5. Lubricate  and fit the  input shaft cover  and ‘0’ ring 
seal  using  special tool 
LST123. 
ST1934M ST1931M 
..I .. .,. ....-. . . .I. I , .. , ..... :’ 
37  
						

							57 
S7 
STEERING 
6. Secure preload  setting tool R01016 to the  input 
shaft  with the  grub  screw. Wind  string  round the 
tool  and tie a spring  balance  to  the free end 
of the 
string.  Whilst turning  the  input shaft cover 
clockwise,  pull the spring  balance  until  a  constant 
preload  reading 
of 0,69 Nm is achieved. 
6 / 
Fitting sector shaft and piston-rack assembly 
7. Fit the  sector  shaft to the housing  and  engage it 
with the input  shaft worm  in the  straight  ahead 
position. 
8. Screw-on,  to the  sector  shaft adjuster,  the sector 
shaft  cover  and secure  with two or three 
of the six 
retaining  screws. 
9. Turn the adjuster  screw  clockwise,  with a  6 mm 
hexagonal  key, until  the sector  shaft  just  makes 
contact  with the input shaft worm. 
W ST1937M 
10. Without  moving the adjuster,  fit the  locknut  whilst 
restraining  the  adjuster  screw with the 
6 mm key 
and  just  nip  the  locknut with an  open
-ended 
spanner. 
ST1938M 
11. 
12. 
13. 
Temporarily  fit the  drop  arm and tighten the 
locknut  until no clearance is felt between  the sector 
shaft and  drop arm. 
Rotate  the  input shaft one turn  clockwise,  then 
turn  the  shaft  back to the  straight  ahead position 
whilst  noting  the point  at which  the backlash 
to the 
drop  arm disappears 
or is taken-up. 
Repeat  instruction 
12 and rotate  the input  shaft 
anri-ciockwise on to the  opposite iocic. 
38  
						

							~ . .. .. . .. ... 
... .. ..,, .- /. . 
STEERING 1571 
14. 
If the  difference  between  the two  points  at which 
the  backlash  is taken
-up  or disappears  is greater 
than 
90 (94 of a  turn)  it will  be necessary  to change 
the  shimming  behind the input  shaft inner  bearing 
cup. 
15. If  the  shimming  requires adjustment,  add a shim  on 
right
-hand  drive  steering  boxes if backlash starts 
too  quickly  on clockwise  rotation. Should backlash 
start 
too quickly  for anti-clockwise  rotation, 
remove  a  shim. 
For a  left-hand drive steering  box, 
reverse  :he foregoing  procedure. 
* 
NOTE: If it is necessary  to perform instruction 15, 
instructions 3 to 13 must be repeated afterwards. 
16. Remove the drop  arm  and whilst  restraining  the 
sector  shaft  adjuster, 
so that it does  not turn, 
remove  the locknut. 
17.  Remove  the sector  shaft  cover  screws  and while 
still  restraining  the  adjuster,  unscrew  clockwise, 
the  cover  from the sector  shaft  and  withdraw  the 
sector shaft. 
18. Lubricate  the rack  piston  plastic  seal and insert the 
piston  into the piston  bore, rack end first,  as in 
instruction 
11 of the  dismantling  procedure, to a 
depth 
of 37 mm below  the lip of the bore. 
19. Lubricate  and fit :he  sector  shaft in the straight 
ahead  position. 
20.  Lubricate  and  fit 
0 ring  seal to the  sector  shaft 
cover. 
21.  Restrain the sector  shaft adjuster  and screw
-on the 
cover,  reversing  instruction  17.  Secure with the six 
bolts,  tightening  evenly  to 
25 to 30 Nm (18 to 
22  lbs  ft). 
22.  Restrain  the  sector  shaft  adjuster  and fit and 
tighten  the locknut,  as instruction 
10. 
23.  Fit  and  lubricate  an 0 ring  seal  to  the rack 
adjuster  screw. 
24.  Fit the  rack  pad and  spring  noting that the larger 
flat  side  of the pad 
is towards the rack. 
25.  Screw
-in the  rack  pad adjuster  until the head  is 
4 mm from the steering  box face. 
I ST1943M 
39  
						

							1571 STEERING 
26. Lubricate  and fit an ‘0’ ring  seal to the piston-rack 
cover. 
27. 
Fit the  piston  cover  to  steering  box.  Align the 
retaining  ring hole  in the  cover  with the cut
-out  in 
steering  box housing  and  insert  hooked  end 
of the 
retaining  ring in the 
hole. Using  special  tool 
LST123, rotate the cover  anti-clockwise  to feed  the 
ring  into  the  groove  until the ring  is fully  seated. 
This 
is a reversal of instruction 3 of the  dismantling 
procedure. 
. 
ST1956M  
28.  Temporarily fit the drop  arm and secure  with the 
nut 
so that no backlash  is present  between  the arm 
and  sector  shaft.  Set the steering  in the  straight 
ahead  position. 
29. Fit the prcload  setting tool R01016 to the  input 
shaft  and  secure  with the  grub  screw. Rotate  the 
input  shaft in both  directions  clockwise and  anti
- 
clockwise % to 3/4 of a turn  to check  the backlash 
distribution. 
30. To check  the drop  arm  angular  travel for a LHD 
drive  steering  box use the preload  setting  tool  to 
turn  the input  shaft  two turns  clockwise  and  one 
and  three
-quarter  turns anti-clockwise.  For RHD 
drive boxes, the opposite applies. 
31. Remove the drop arm. 
32.  Return 
to the straight  ahead position  and screw  the 
rack  adjuster  clockwise  until  the adjuster pad  just 
contacts the  pad.  33. 
Restrain  the sector shaft  adjuster, as in instruction 
10, and  tighten  the locknut  to 70 to 90 Nm (52 to 
66 Ibs/ft). 
34.  Secure  the  rack adjuster  with the grub  screw, 
reversing  the dismantling  procedure instruction 
5. 
ST 
35. Secure the worm  adjuster  with a new  pin. If 
necessary,  drill  a new 
4 mm hole in the  adjuster 
through  the hole 
in the  steering  box housing to 
locate  the pin.  Check, before  drilling that the new 
hole  will not break  into the side  of the  existing 
hole. 
40  
						

							STEERING 
n 
57 
/ 
ST1947M 
Fitting sector shaft oil seal 
40. Lubricate  the oil seal  and seal-saver LST12.5, and 
slide 
the seal  over  the tool,  lip side leading. 
fully home into  the housing. 
41. Using  the seal-driver  part of the tool,  push thc seal 37. Withdraw  the conical  seal-saver  and  place  the 
lower  part 
of the tool  with  the seal,  lip side 
downwards,  over the input  shaft. 
38. Place the seal-driver  part of the tool on top of the 
seal  and drive 
it fully home. 
ST1948M 
38 
ST1950M 
42. Fit the  steel washer  and  secure the  assembly with 
the  circlip. 
39. Fit the  anti-extrustion  washer  and secure  the 
assembly  with the wire circlip. 
42 
ST1951M  I 
41  
						

							STEERING 
43. Fit the  drop  arm,  tab washer  and nut.  Tighten  the 
nut  to 
170 to 180 Nm (125 to 132 Ibs/ft). Fold  one 
side 
of the  tab  washer  over the drop  arm and the 
other  over a flat  against  the nut. 
44. Refit  the steering box to the  vehicle  and bleed  the 
hydraulic  system. 
NOTE: Bleeding and test of the power steering box 
is the same  as that for the Adwest Lightweight box. 
42