Land Rover Defender 90 110 Workshop 1984 Rover Manual

							SUSPENSION E( 
Tyrc Size 
750 x 16 Michelin XS 
750 x 16  Avon  Rangers 
750 
x 16  (All  others) 
c J I. .; 50. Coat  a joint  washer  both sides  with sealing 
compound  and  place in position  on the  lower 
swivel  pin. 
51. Fit the  lower  pin with lip outboard. Do not  secure 
with  bolts  at this  stage. 
52. Lubricate  the Railko  bush with an EP  oil and  fit the 
top  swivel  pin  with  existing  shims and fit the 
securing  bolts and jump  hose  bracket  (do not 
tighten). 
53.  Coat  the threads  of the  lower  swivel  pin bolts  with 
Loctite  270 and  fit,  together  with the  brake  disc 
shield  bracket,  and tighten  to 
22 to 28 Nm (16 to 
21 Ibf ft). 
54. Tighten  the  top swivel  pin  securing bolts to 60 to 
70 Nm (44 to 52 Ibf ft). 
55. To check  the top  swivel pin  pre-load attach a spring 
balance  to the  track
-rod  ball  joint bore  and pull  the 
balance 
to determine the  effort required  to turn  the 
swivel.  The resistance,  once 
the initial  inertia  has 
been  overcome,  should be 
3,60 to 430 Kg (8 to 
10 Ibs). If necessary,  adjust by removing or adding 
shims 
to the  top  swivel pin  as required. 
ir .R ., ” *’ . ,.. 
% - 
Dim ‘A’ & 0,25 mm 
54,OO mm 
54,OO mm 
51.00 mm 
63. Fit the  stub  axle  with  the keyway uppermost at 
12 o’clock. At this  stage it is most  important  to 
ensure  that  the  constant  velocity joint bearing 
journal  engages  fully into the bronze  bush in the 
rear  of the  stub 
axlc before the stub  axle is secured 
with  bolts.  Damage  to the  bush  can occur 
if this 
precaution  is not  observed.  To ensure  proper 
engagement,  grasp the stub  axle with  one hand  and 
with  the other  pull the axle  shaft into the bush. The 
shaft  and bush  are correctly  engaged  when  the end 
of the axle  shaft  splines  are flush  with the  end of 
the  stub  axle. This condition  must be maintained 
during  all ensuing assembly  operations. 
64.  Place  the mud shield  in position and secure  the stub 
axle  to  the  swivel pin housing  with the six bolts 
using  Loctite  270 and  evenly  tighten  to 60 to 
70 Nm 
(44 to 52 Ibf  ft). 
65. 
To complete  the reassembly,  follow instructions 25 
to 41  covering  front hub overhaul. 
66.  Check  that the swivel  pin  housing  drain plug is 
tightly  fitted and remove the  filler level 
plug. 
67. Inject  approximately 0,28 litres (% pint)  of 
recommended 
EP oil  until  the oil begins  to run out 
of the filler hole. Fit and  tighten  the  plug  and wipe 
away  any 
surplus oil. 
68.  Set 
the steering  lock-stop  bolts  to providc a 
clearance  between  the tyre  wall  and  radius  arm in 
accordance  with the dimensions  below. This 
dimension  however, must  bc set to 56 
mm, 
irrespective  of tyre  size  and type where  steering 
gaiters  are fitted. 
56.  Liberally  apply 
- but  do not pack - a 
recommendcd grease  between  the lips of  the swivel 
oil  seal 
(2,5 to 4,O grams). 
57. Secure  the oil seal and joint washer  with the 
retaining  plate and securing  bolts tightening  evenly 
to  7 
to 10 Nm (5 to 7 Ibf  ft). 
58. Fit the  track-rod  and  drag  link and secure  with new 
split pins. 
59. Fit  the  brake  disc shield. 
60.  Loosely  fit the 
lock stop  bolt and  nut for later 
adjustment 
. 
-- 
ST18OlM Fit  drive  shaft and stub  axle 
61. Place  a new  joint washer  in position  on the swivel 
pin  housing  to stub  axle mating face. 
62. Taking care not  to damage  the axle  shaft oil seals, 
insert 
the axle  shaft,  and  when the differential 
splines  are engaged,  push the assembly  home. 
,. 
7  
						

							64 
OVERHAUL REAR HUB ASSEMBLY 
Service tool: 18G 1349 seal replacer 
Dismantle 
NOTE:  The 
oil catcher mentioned in instructions  7 and 
17, 
is fitted  to 110 models  only. 
SUSPENSION 
1. Slacken  the  road wheel retaining nuts,  jack  up the 
vehicle,  lower onto axle stands  and  remove the 
road  wheels. 
2.  Remove  the three brake  drum retaining screws and 
withdraw  the brake  drum. If necessary,  slacken the 
brake  adjuster to  facilitate removal. 
3. Lever off the hub  cap  and  remove  the axle  shaft 
circlip. 
4. Remove  the six bolts  and withdraw  the hub  driving 
5. Unlock the tab washer,  remove the outer and inner 
1 member and joint washer. 
locknuts  and keyed  thrust washer. 
6. Withdraw  the hub  complete  with inner  and  outer 
taper  roller bearings  and dual  lipped seal. 
7. If required,  remove  the oil catcher  and  bearing 
sleeve  by removing  the six brake  backplate 
retaining nuts  and bolts. 
Overhaul  hub 
8. Remove the dual  lipped  seal  and  inner bearing 
9. If new bearings  are to be fitted drift  or press  out the 
10. Examine  the road  wheel  studs and  renew any worn 
11. Press  in new  bearing cups  up to the  shoulder. 
12.  Examine  the oil seal  housing  in the  hub  and 
remove any  burrs that could  damage the  seal. 
13. Pack the inner bearing  with Shell Retinax A grease 
or  equivalent  and fit to the  hub. 
14.  While  taking  care not to touch  the seal  lips, 
liberally  smear 
- not pack - the cavity  between 
the  seal  lips with  Shell Retinax 
A or equivalent. 
from the hub. 
old bearing 
cups. 
or  damaged ones. 
$3 %*’ 
8  
						

							SUSPENSION 164 
15. To avoid possible  damage to the  seal  and to ensure 
the  correct  depth into the hub,  press
-in the  seal,  lip 
side leading,  using special  tool 
18G 1349.  16. 
If 
this tool 
is not  available  obtain a suitable  tube 
that  will 
fit exactly  on the four diametrically 
opposed  pads 
in the channel  round the seal  on the 
opposite  side to the  lip and 
with the  lip leading 
press
-in  the  seal so that it is recessed 4,s to 5,3 m 
(0.190 to 0.210 in) from  the rear  face of the  hub. 
.. . .. .. ... ,..,. , i ., . , , .. 
110 REAR  AXLE HUB 
2 
1. Dust cap. 10. Brake dru!??. 
2. Circlip.  11. Hub. 
3. Driving  member. 12. Outer bearing. 
4. Joint washer.  13. Oil seal. 
5. Locknut.  14. Oil catcher. 
6. Lock  washer. 
7.  Adjusting  nut. 
8. Key washer. 
9. Outer  bearing.  18. Half-shaft. 
15. 
Brake  back plate  assembly. 
16.  Stub  axle. 
17.  Joint  washer. 
9  
						

							SUSPENSION 
Reassemble hub to axle 
17. If removed,  assemble the backplate  and oil catcher 
to  the  axle  having  first  smeared  Hylomar 
SQ32M 
on the  face of the oil catcher  to seal  it  to  the 
backplate. Ensure  that the milled  slot and  the drain 
hole 
in the  backplate line up at the  bottom. Secure 
the  assembly 
to the  axle  with  the six bolts  and nuts 
and 
tightcn to  the  correct torque. 
ST503M 
18.  Before  fitting the hub, ensurc that thc journal  on 
which  the  dual  lipped  seal runs  is clean  and free 
from 
imperfcctions that  could  damage  the seal. 
19. Fit the hub  to the  bearing  sleeve, pack the  outer 
bearing  with grease  and fit 
to the hub. 
20.  Fit the  keyed  thrust  washer  and  adjusting inner 
nut.  Tighten  the nut,  by hand,  whilst  rotating  the 
hub  until  all the end
-play is taken up. 
21. Mount  a dial test  indicator so that the stylus rest  on 
the  adjusting  nut. Slacken the  nut back 
to obtain  an 
end
-float of 0,050  to 0,101 mm (0.002 to 0.004 in). 
22. 
Fit the  tab washer  and outer  locknut.  Tighten  the 
locknut,  re
-check the end-float and  lock the nuts. 
ST632M 
10 
23.  Using  a  new joint  washer,  fit the  hub  driving e 
member  and tighten  the retaining  bolts and spring *‘ 
washers  to 60 to 70 Nm (44 to 52  Ibf  ft). 
24.  Fit the  circlip  to the  axle  shaft,  ensuring  that 
it 
locates  correctly  in the  groove. 
25.  Fit  the  hub cap, 
if necessary  using a new ‘0’ ring 
seal. 
26.  Fit the  brake  drum and secure, 
if necessary  with 
new  screws. 
27.  Adjust  the brake  shoes to  the drum. 
28.  Fit the road wheels,  using new nuts 
if necessary. 
29.  Remove  the vehicle  from the axle  stands  and 
finally  tighten  the wheel  nuts to the correct torque. 
REAR HUBS 
With  inner  and  outer seals.  From axle numbers 
onwards 
Land Rover 
90 
Land  Rover  110 
22308284B 
21 S22955B 
REMOVE  AND OVERHAUL 
Special tools: 
Oil  seal  replacer 
LST 550-5 
Drift for seal replacer MS 550 or 186134 
Hub  nut spanner 606435 
Remove 
1. Jack-up  the  vehicle,  lower onto axle stands  and 
remove  the road  wheels. 
2.  Remove the  two brake drum  retaining screws and 
withdraw  the brake  drum. 
If necessary,  slacken  the 
brake adjuster  to facilitate removal. 
3. Prise-off  the hub  cap. 
4. Remove  the circlip. 
5. Remove  the  five bolts  and withdraw  the hub 
driving  member  and joint  washer. 
6.  Prise
-up  the  lock  washer  and remove  the  outer 
locknut  and inner  adjusting  nut. 
7.  Withdraw  the  hub  complete  with  with the inner 
and  outer  seals,  seal track  spacer,  and inner  and 
outer  taper roller bearings. 
8. If the  stub  axle is damaged  or scored  remove  and 
discard 
it by  removing  the six brake  back  plate 
retaining nuts and bo!ts. 
Overhaul  hub 
9. Remove the  seal track spaccr and outer  seal. 
10. Remove the outer bearing  cone. 
continued f ”’ ‘IJ  
						

							SUSPENSION 
S. I ... 
.I 11. Remove the inner seal and bearing  cone. 
12.  If new  bearings  are to be  fitted  drift or press  out the 
old  cups. 
13.  Degrease  and examine  the hub  for  cracks  and 
damage  and  renew 
if necessary.  Renew  hub if 
wheel studs are faulty. 
Assemble 
14. If removed,  fit the  stub  axle to the  axle  casing  with 
a new joint washer  and secure  with the six nuts  and 
bolts  and tighten  to the  correct torque. 
15. Fit  new  inner  and outer  bearing  cups to the hub, 
ensuring  that they  are drifted 
or pressed  squarely 
into  position. 
16. Fit the  inner  bearing  cone and pack with  one of the 
recommended  hub greases. 
- Fitting  inner oil seal 
17. Clean the  hub oil  seal  housing and  ensure that  the 
seal locating  surface is smooth  and the chamfer  on 
the  leading  edge is also  smooth  and  free from 
burrs. 
18. Examine  the  new  seal and ensure  that it is  clean, 
undamaged  and that  the garter  spring  is properly 
located. Even  a  small scratch  on  the seal  lip could 
impair  its efficiency. 
19.  Although  the new  seal is already  pre
-greased  by 
the  manufacturer,  apply one 
of the recommended 
hub  bearing  greases  to the  outside  diameter 
of the 
seal, before fitting, taking care  not to damage  the 
lip. 
20. Place  the seal,  lip side leading,  squarely on the hub 
and  using  the 
76 mm end of seal replacer  tool 
LST 550-5 and drift 550 or 18 G 134 drive  the seal 
into  position  to the depth  determined  by the  tool. 
Fitting  outer oil seal 
21.  Fit the  new  outer  bearing cone  and pack  with one 
of  the  recommended  hub greases. 
22.  Carry  out instructions 
17 to 19 but  insert  the seal 
with  the lip side  trailing. 
23.  Place  the seal, lip side leading,  squarely on the hub 
and  using  the 
72 mm end of seal replacer tool 
LST 550-5 and drift 550 or 18 G 134,  drive  the seal 
into  position 
to the depth  determined  by the  tool. 
Fitting  hub to stub  axle 
24. Smear  the  lips of both seals with one of the 
recommended  greases. 
This is important since a 
dry seal  can  be destroyed  during the first  few 
revolutions 
of the hub. 
25. Select  a  new seal  track  spacer  and  check that the 
outer  diameter  is smooth and  free  from blemishes 
26. Taking care not  to damage  the seal  lips fit the hub 
assembly  to the stub  axle. 
Do not allow  the weight 
of  the  hub 
to rest,  even  temporarily, on the  outer 
seal otherwise  damage  and distortion could  occur. 
Therefore  hold the hut  clear 
of the stub axle until 
the  seal  track spacer 
is fitted. 
27. Carefully fit the seal  track spacer,  seal lip leading. 
28. Fit  the  hub  inner  nut  and  using spanner  606435 
tighten  the adjusting  nut whilst slowly  revolving 
the 
hub until all  end-float is removed  then back-off the 
nut approximately half-a-turn. 
29.  Mount  a dial test indicator and bracket 
on the hub 
so that  the stylus  rests in a loaded  condition on the 
nut.  Check  the end
-float  which  must be 0,013 to 
0,010 mm (0.0005 to 0.0004 in). Adjust  the  nut as 
necessary to achieve this. 
30,  Fit the  locker  and  locknut  and  tighten against  the 
adjusting  nut. 
31. Rotate the hub  several times  to settle the bearings 
then  re
-check  the end-float. 
32.  Bend  one segment 
of the  locker over  the adjusting nut 
and  another,  diametrically opposite,  over the locknut. 
V/ , 
32, 
32’ 
ST1800M Y// 
33. Using  a  new joint  washer,  fit the  hub  driving 
member  and secure  with the five  bolts  and tighten 
evenly  to the  correct  torque. 
34. Fit the  circlip  to the  axle  shaft  ensuring  that it is 
properly  seated in the groove. 
35. Fit  the hub cap. 
36. Fit the  road  wheels  and secure  with the nuts. 
Jack
-up  the  vehicle,  remove axle stands and lower 
vehicle to ground.  Finally  tighten  the road  wheel 
nuts  to the  correct  torque. 
and  that  there  are no burrs 
on the  chamfered 
leading  edge. 
11  
						

							I64 1 SUSPENSION 
ST 
KEY TO HUB COMPONENTS 
1. Hub cap. 
2.  Circlip. 
3.  Spring washer
- hub  driving  member bolt. 
4. Hub driving  member. 
5. Hub driving  member  bolts. 
6. Brake drum retaining  screws. 
8. Outer bearing  cup. 
9. Inner bearing  cup. 
10. Inner bearing  cone. 
11. End-float adjustingnut. 
12. Inner  oil seal. 
13.  Joint  washer. 
7. Otter bearing cone. 
stub axle to axle  casing 14. Locknut. 
15. Bolt. 
16. Axle  shaft 
17. Locknut. 
18. Lock washer. 
19. Joint  washer. 
21.  Hub  casting. 
22.  Brake  drum. 
23.  Outer  oil seal. 
24.  Road  wheel 
stud. 
25. Stub  axle. 
20. %a! !El& SFX€!r. 
12  
						

							SUSPENSION 164 I 
. 
OVERHAUL REAR SUSPENSION 
Remove  the lower  links . .. .A c. -. . 
1. Jack up the rear of the vehicle  and lower on to axle 
stands. 
2.  Remove 
the nut  and  bolt  retaining  the lower link to 
the  axle  bracket. 
3. Remove  the three  nuts and  bolts  retaining  the 
foward  end of the  link  to the  chassis  bracket. 
4.  Withdraw  the lower  link from  the vehicle. 
5.  Remove  the  locknut and washer  and  remove  the 
flexible  mounting from  the link. 
Renew the bushes 
6. Press  out the bush  from  the rear end of the  lower 
link. 
7.  Press  in a new  bush  squarely  into the link. 
Fit the lower  link 
8. Assemble  the flexible  mounting  to the  link  and 
secure  with the  locknut  but  do not  tighten  at this 
stage. 
9. Fit  the  link  to the vehicle,  securing  the front  end of 
the 
link to the  chassis  bracket  with the three  nuts 
and  bolts. 
10.  Assemble  the  rear end 
of the link to the axle 
bracket  and retain  with the nut and  bolt, but do not 
tighten  at this  stage. 
11. Lower  the  vehicle to the  ground  and  allow the 
suspension  to settle. 
12.  Tighten  the nut and bolt at  the rear  end of the  link. 
13.  Tighten  the  forward  locknut to 176 
Nm 
(130  lbf ft). 
Remove upper links 
22.  Using  ball joint extractor tool R01006 or a suitable 
proprietry  tool  remove  the ball joint  from the axle 
bracket. 
23.  Remove the  pivot bracket  complete  with the ball 
joint  and 
if fitted,  the  lower ball joint of the 
levelling  unit. 
24.  Remove  the two  bolts  securing  the ball  joint  to the 
pivot  bracket  and press  the  ball joint  from  the 
bracket. 
NOTE: Replacement  ball  joints  are supplied as 
complete assemblies packed  with grease. 
25. Using  two  bolts  as a guide  to ensure  correct 
alignment press  the knurled  ball joint into  the 
pivot 
bracket and secure  with the two nuts and bolts. 
Assemble upper links  and ball joints 
26.  Fit  the pivot  bracket  ball joint  and bracket  to the 
axle and  secure with the plain washer 
castle nut and 
split  pin. Tighten  the nut  to 176 
Nm (130 Ibf  ft). 
27. 
Fit the  levelling  unit, if used. 
28.  Assemble  the upper links to the  chassis  attachment 
brackets  but do not  at this  stage  fully tighten  the 
pivot nut  and bolt. 
29.  Fit the upper  link 
assemblics to the chassis with the 
six  nuts  and bolts,  (three  each side).  Note the 
positions of the bolt  heads.  Tighten  the  nuts to 
47 Nm (35 lbf ft). 
30.  Secure the  rear ends of the  upper  links 
to the pivot 
bracket  and tighten  the two  nuts  and  bolts and 
tighten  to 115 
Nm (85  Ibf ft). 
31. Remove  the jack  from  the chassis,  allow thc 
suspension  to settle  and tighten  upper link  pivot 
bolts. 
14. 
15. 
16. 
17. 
18. 
19. 
Jack  up the  vehicle  under the chassis so that  the 
rear  axle 
is freely  suspended. 
Remove nuts and bolts retaining the upper link 
bracket to the chassis  frame. 
Remove the  two nuts and  bolts securing  the upper 
links  to the  pivot  bracket. 
Withdraw  the upper links complete  with the chassis 
attachment  brackets from vehicle. 
Remove  the 
nut and bolt  retaining  forward  end of 
the  link  to the  chassis  bracket  and  separate the  two 
parts. 
Press out  the bush  from  the forward  end of the 
Renew anti-roll bar bushes  and ball joints 
32.  Remove  the two nuts  and bolts  securing  the anti- 
roll bar to the axle  link. 
33. Remove  the eight  nuts  and  bolts (four  each side) 
retaining  the anti
-roll  bar to  the chassis  and remove 
the bar  from the vehicle. 
34.  Remove the  split pin and  castle  nut and  remove 
the 
ball joint  and link  from  the axle  location. 
If the ball  joint requires replacement  the complete 
link must  be renewed. 
35.  Renew  the  rubbers  and fit the  anti
-roll  bar  to  the 
chassis  and  secure  with the eight  bolts and nuts 
tightening  to 24 
Nm (18 lbf ft). 
36.  Fit the  ball  joint  and link  to the  axle  location and links 2.d squ.re!y press in new bushes. 
Renew pivot bracket  ball joint tighten the castle nut  to  176 Nm (130 lbf ft) and fit 
a new  split  pin. --  - 20. Remove  the levelling unit -if fitted. 
21.  Remove  the split  pin, castle  nut  and plain  washer  37. 
Fit the  anti-roll  bar  to the  ball  joint  link and fit new 
bushes  in the  sequence  illustrated  and tighten  the 
nuts and bolts, 
to the  correct  torque. 
13 
securing  the ball  joint to the pivot  bracket.  
						

							-- I 12 3 
1. Salisbury axle casing 
2. Anti-roll bar 
3. Boge  self levelling unit 
4. Levelling  unit upper  ball joint  assembly 
5. Levelling unit  lower ball joint  assembly 
6. Fulcrum bracket 
7. Fulcrum  bracket ball joint  assembly 
8.  Suspension  top links 
9. Top link mounting brackets 
10. 
Top link  bushes 
11. Lower links 
f*) ti 
REAR  SUSPENSION 
A1 
12.  Lower link flexible  bush assembly 
13. Lower link bush and  bolt  assembly 
14. Coil spring assembly 
15. 
Bumpstop 
16. Shock  absorber 
17.  Shock  absorber  top bush assembly 
18.  Shock  absorber lower bush assembly 
19. Anti-roll bar bush  and strap  assembly 
20.  Anti
-roll  bar  ball joint and  link assembly 
21. Heavy duty  Rover axle casing 
18  
						

							SUSPENSION 
A Boge Hydromat levelling  unit is located  in the  centre 
of  the rear  axle. 
When  the vehicle  is unladen  the  levelling unit  has little 
effect.  The 
unit is self-energising  and hence  the vehicle 
has  to be  driven  before  the unit  becomes  effective, the 
time  taken  for this to  happen  being dependant  upon the 
vehicle  load,  the  speed at which  it is  driven  and  the 
roughness  of the  terrain  being crossed. 
If the  vehicle is overloaded  the  unit will fail to level 
fully  and  more  frequent  bump  stop contact will be 
noticed. 
Should  the vehicle  be left  for a lengthy  period e.g. 
overnight,  in a  laden  condition, 
it may settle. This is 
due to  normal  internal 
fluid movement  in the  unit  and 
is not detrimental to  the unit performance. 
Before  carrying  out  the checks  below,  verify that  the 
vehicle  is being  operated  within the specified  maximum 
loading capabilities. 
If the  levelling unit  is then  believed 
to  be  at fault,  the procedure  below should  be followed. 
Whilst  slight 
oil seepage IS permissible,  the unit  should 
be  renewed 
if there  is an  excessive  oil leak. 
1.  Remove  excessive  mud  deposits from underneath 
the  vehicle  and  any  heavy  items  from inside  the 
vehicle  that are not  part 
of the original  equipment. 
2.  Measure  the clearance between  the  rear axle bump 
pad  and the  bump  stop rubber  at the  front  outer 
corner  on both  sides 
of the  vehicle,  dimension A. 
The average  clearance  should be in excess of 
67 mm (2.8  in). 
3. If thc bump stop  clearance is less  than  the above 
figure  remove  the  rear springs and  check the free 
length against  the following  data in the  chart. 
4. Renew  any spnng  where  the free length  is more 
than  20 
mm (0.787  in) shorter  than the figures  in 
the  chart. 
5. Having refitted or renewed  any springs  repeat the 
clearance  check as described  above.  If the  average 
bump  clearance 
is still  less  than 67 mm (2.8 in) 
renew 
the levelling  unit. 
. ., ,. 
. 
L 
64 
r-- Steering 
Side 
1 R.H. 
Part Rate Number  Free length  Colour 
Number 
Nm (Ibhn) ofcoils (mm) Code 
t--- PASSENGER 1 R.H. 
One Green 
and 
onc 
White stripe ._ .- NRC  7000  31.5 (180)  6 400 
6. Load  weights  to the  value of 650 kg (1143  Ibs) 
evenly  over the rear  load  area of the  vehicle  and 
leave  it to  settle undisturbed  for minimum  period 
of  thirty  minutes. 
7.  With  the driving  seat occupied 
or with  an 
approximate  equivalent weight of 75 
kg (165 Ibs) 
check  the bump  stop clearance  and  note the 
measurPment. 
8. Drive  the vehicle  on a test  route  approximately 
5 km (3 miles)  in length  over undulating  roads  or 
graded tracks.  At the  completion  of the  drive  bring 
the  vehicle  to  rest  by light  brake  application 
so as 
not  to disturb  the vehicle loading. 
9. Without  disturbing  the vehicle  load  and  with thc 
driving seat occupied,  check the  bump  stop 
clearance  and  note the reading,  which must be 
in 
excess  of 45 mm (average). 
10.  Subtract the  reading obtained  under  Instruction 
7 
from that  obtained  under Instruction  9. If the 
change 
in clearance  is in  excess  of 10 mm (0.394 in) 
the  levelling  unit is functioning correctly. 
11. If the figures  obtained  in instructions 9  and 10 do 
not  exceed 
45 mm and 10 mm (1.77 and  0.39  in) 
respectively  unload the vehicle  and renew  the 
levelling  unit. 
PASSENGER 
One Green 
White stripe 
NRC 
7000  31.5  (180)  6 
400 and onc 
Two Blue 
stripes 
DRIVER I NRC 
6388  31.5 (180) I 6 I 412 1 
Two Blue 
stripes 
DRIVER I NRC6388 131.5 
(180) 1 6 1 412 1 
15  
						

							1641 SUSPENSION 
REMOVE LEVELLING  UNIT - where fitted 
WARNING:  The levelling  unit contains  pressurised  gas 
and  must  not be dismantled  nor the casing  screws 
removed.  Repair 
is by replacement of complete  unit 
only. 
1. Raise and  support the vehicle  under the chassis and 
use  a jack 
to support  the weight of the axle. 
2. Disconnect the upper  links at the pivot  bracket. 
3.  Ease  up the 
levclling unit  lower  gaiter and  unscrew 
the  lower  ball joint  at the  push  rod using  thin jawed 
spanners. 
4. Release the  webbing strap from the chassis. 
5. Remove  the four  nuts  securing the  top bracket  to 
the  chassis  and withdraw  the  levelling  unit 
complete  with bracket. 
Renew  levelling  unit ball joints 
The-ball joints for the levelling unit  may be dismantled 
for 
clcaning and cxamination. 
6.  Unscrew  the  lower ball joint  from thc pivot 
7.  Unscrew 
thc ball  joint  from the top bracket. 
8. Reassemble  the  ball joints,  packing  with 
Dextagrease 
G.P. or  equivalent  or if necessary 
renew the joints 
if worn. 
9. Check  the  condition  of the gaitcrs and  renew if 
necessary. 
1 
bracket. 
Fit levelling  unit 
10. Ensure  the ball  pin  threads are clean  and  smear 
Loctite  grade CVX  on the  ball pin  threads. 
11. Fit the upper  ball joint  to  the  levelling unit and 
secure the gaiter. 
12. Fit  the  top  bracket  complete with  levelling  unit to 
the chassis and sccure with the four  nuts  and 
tighten  to  47 
Nm (35 Ibf ft). 
13.  Fit  the levelling  unit 
to the lower  ball joint and 
secure the gaiter. 
14.  Attach  the webbing  strap to the  chassis  cross 
member. 
15. Fit  the  upper  links to the  pivot  bracket  and retain 
with  the  two  bolts and nuts  but do 
not tighten  at 
this  stage. 
16.  Remove  the jack  in support 
of the axle  and the 
support  from under  the chassis. 
17.  Allow  the suspension 
to settle  and then  tighten  the 
two  bolts  and nuts  retaining the upper  links 
to the 
pivot  bracket  to 
thc correct torque. 
SPRINGS AND SHOCK ABSORBERS 
Remove  rear springs 
1. Slacken the rLAr road  wheel  nuts and  raise the rear 
of  the 
vehick and  lower  the  chassis on the  axle 
stands 
or similar  supports  and  remove  the road 
wheels. 
16 
2. Support the  weight of the axle  with  a jack. 
3. Disconnect  the shock  absorbers  at the  lower  end. 
4. Remove the spring  retainer plate. 
5. Lower the axle sufficiently  to withdraw the spring, 
but  take  care  not to stretch  the flexible  brake hose 
by  lowering  the axle  too far. 
6. Remove the  spring pan. 
Renew rear springs 
7. Fit the spring  pan and retainer  plate. 
8. Fit the spring  into the chassis  top location  and using 
9. Secure  the  shock  absorbers with the  rubbers 
10. Remove  the axle  support,  fit the  road  wheels and 
11. Finally tighten the road  wheel nuts. 
a 
turning  motion 
fit the spring  to the  axle  pan. 
correctly  located. 
lower  the vehicle  to ground. 
- Remove  shock absorbers ,p- ..h 
12. Slacken  the  road  wheel nuts, raise  the  rear of the 
vehicle  and support  it under  the axle  and remove 
the  road wheels. 
13. Remove  the shock  absorber  upper  and lower 
retaining  nuts and rubbers. 
14.  Remove the  shock absorber  from the top  locating 
shaft and withdraw 
it from  the vehicle. 
--. h 
Test  shock  absorbers 
15. Hold the shock  absorber  vertically  in a vice,  being 
careful 
not to damage the  threads. 
16. The shock  absorber  employs  differential  damping 
having  greater  resistance  on the  extension  stroke. 
Check  operation  by extending  and compressing the 
shock  absorber. 
Resistance  should be uniform  throughout  the 
length  of each  stroke.  If resistance  is erratic 
or 
weak,  renew  the shock  absorber.  When checking 
resistance  a new  shock  absorber  may be used  for 
comparison. 
To ensure  that the new  shock 
absorber  is primed,  fully extend  and compress  the 
unit several  times before  testing begins. 
Fit shock  absorbers 
17. Fit the shock  absorbers  using new rubbers  and  fit 
18. Fit the  road  wheels,  lower the vehicle  and finally 
the 
lower  rubbers  and caps  in the order  illustrated. 
tighten 
the road  wheel  nuts.