Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							54FRONT AXLE AND FINAL DRIVE
2
OVERHAUL FRONT STUB AXLE, CONSTANT VELOCITY JOINT
AND SWIVEL PIN HOUSING
Service repair no - 60.15.43.
Remove stub axle, axle shaft and constant
velocity joint.
1.Remove front hub assembly.
See Repair,
Front Hub Assembly
2.Drain swivel pin housing and refit plug.
NOTE: On later vehicles the swivel pin
housing is filled with grease for life
service. The level and drain plugs have
been deleted.
3.Remove 6 bolts retaining stub axle to swivel
housing.
4.Remove mud shield.
5.Remove stub axle and joint washer.
6.Pull out axle shaft and constant velocity joint
from axle casing.
Remove constant velocity joint from axle shaft
7.Hold axle shaft firmly in a soft jawed vice.
8.Using a soft mallet drive constant velocity joint
from shaft.
9.Remove circlip and collar from axle shaft.
Constant velocity joint
10.Mark positions of constant velocity joint, inner
and outer race and cage for reassembly.
11.Swivel cage and inner race to remove balls. 
						

							FRONT AXLE AND FINAL DRIVE
3
OVERHAUL 12.Examine all components in particular inner and
outer track, cage balls and bearing surfaces for
damage and excessive wear.
13.Maximum acceptable end-float on assembled
joint 0,64mm, 0.025 in. Renew if worn or
damaged. Lubricate with a recommended oil
during assembly.
Fit constant velocity joint to axle
14.Fit collar and a new circlip.
15.Engage constant velocity joint on axle shaft
splines and using a soft mallet, drive joint in fully.
Renew stub axle,thrust ring, oil seal and bearing
16.Drill and chisel off thrust ring taking care to avoid
damaging stub axle.
17.Remove bearing and oil seal using special tool
LRT-37-004and slide hammerLRT-99-004.
Ensure lip of tool locates behind bearing to to
drive it out.
18.Repeat instruction for removal of oil seal.
19.Lubricate seal and lip with EP90 oil and with
cavity side leading press in a new oil seal using
special toolLRT-54-004.
20.Using special toolLRT-54-005, fit bearing with
its part number visible when fitted, and flush with
end face of stub axle.
21.Press fit a new thrust ring onto stub axle. 
						

							54FRONT AXLE AND FINAL DRIVE
4
OVERHAUL Swivel pin housing assembly
22.Remove brake disc shield bracket.
23.Disconnect track-rod end ball joint from housing.
24.Disconnect drag-link ball joint.
25.Disconnect jump hoses from brake jump hose
bracket.
26.Remove road speed sensor.
27.Remove 6 bolts securing oil seal and retaining
plate to swivel pin housing. Prise seal from
swivel pin housing.
NOTE: Oil seal and retaining plate cannot
be removed until swivel pin bearing
housing is removed.
28.Remove 2 screws securing brake damper/shield
bracket, and lower swivel pin to housing.
29.Withdraw lower swivel pin and joint washer by
tapping protruding lug.
30.Remove top swivel pin retaining bolts complete
with brake jump hose bracket.
31.Remove top swivel pin and shims.
32.Remove swivel pin housing while retrieving
lower taper bearing.
Swivel pin bearing housing
33.Remove 7 bolts securing swivel pin bearing
housing to axle case.
34.Remove and discard oil seal and joint washer.
35.Remove lower swivel pin bearing track.
36.Remove top swivel pin bush housing assembly.
Discard two thrust washers and bearing.
37.If worn, pitted or damaged, renew swivel pin
bearing housing.
38.Fit a new lower swivel pin bearing track.
39.Fit a new bush and bush housing. Ensure
relieved lip of bush housing faces towards rear,
as shown.
40.With seal lips trailing press axle shaft oil seal
flush into rear of housing. Grease lips.
41.Fit new thrust washers and bearing into top
swivel pin bush.
42.Hang swivel pin bearing housing oil seal and
retainer plate over back of housing. Ensure they
are in correct assembly order.
43.Fit a new joint washer and secure swivel pin
bearing housing to axle. Starting with top fixing
dowel bolt. Tighten to
72Nm, 52 lbf ft.
Fit swivel pin housing
44.Grease and fit lower swivel pin bearing to
bearing housing.
45.Place swivel pin housing in position over swivel
pin bearing housing.
46.Using a new joint washer, fit lower swivel pin
with lip outboard. Do not secure with screws at
this stage.
47.Fit a new sensor bush and new oil seal, lip side
leading to top swivel pin.
48.Lubricate with a recommended oil and fit top
swivel pin with existing shims.
49.Coat threads of top swivel pin bolts with Loctite
542. Fit bolts and jump hose bracket (do not
tighten).
50.Coat threads of lower swivel pin screws with
Loctite 270 and fit, together with damper and
shield bracket. Tighten to
25 Nm, 18 lbf ft.
51.Tighten top swivel pin and brake jump hose
bracket securing bolts to
65 Nm, 50 lbf ft.
Check and adjust preload on bearings
52.The preload on bearings to be0,25 to 0,30 mm,
0.010 to 0.012 in withoutswivel housing oil seal
and axle fitted, and reading from centre of swivel
pin. The torque required to turn swivel assembly
from lock to lock to be
2.0 to 2.8 Nm, 1.5 to 2.0
lbf ft.
Adjust by removing or adding shims as
necessary.
53.To take a reading use special tool
LRT-57-024torque test adaptor, with a torque
wrench and extension as shown. 
						

							FRONT AXLE AND FINAL DRIVE
5
OVERHAUL
54.Apply a recommended grease between lips of
swivel housing oil seal.
55.Secure oil seal with retaining plate and securing
bolts. Tighten to
11Nm, 8 lbf ft.
56.Fit track-rod and drag link and secure with new
cotter pins.
57.Loosely fit lock stop bolt for later adjustment.
58.Fit brake disc shield.
Fit driveshaft and stub axle
59.Insert axle shaft, and when differential splines
are engaged, push assembly in fully.
CAUTION: Take care not to damage axle
shaft oil seals.
60.Place a new joint washer in position on swivelpin
housing to stub axle mating face. Coat threads
of stub axle bolts with Loctite 270.
61.Fit stub axle with flat at 12 Oclock position.
CAUTION: Ensure that constant velocity
joint bearing journal is butted against
thrust ring on stub axle before stub axle is
secured.62.Place mud shield in position and secure stub
axle to swivel pin housing with six bolts and
tighten evenly to
65 Nm, 48 lbf ft.
63.Fit brake jump hoses to brake jump hose
bracket.
64.Fit front hub complete assembly.
See Repair,
Front Hub Assembly
65.Fill swivel assembly with correct amount of
lubricant.
See SECTION 10, Maintenance,
Under vehicle maintenance
.
NOTE: Vehicles with a filler plug only must
be filled with 0.33 Litres, 0.75 pt of Molytex
EP 00 grease.
66.Set steering lock stop bolts.
See STEERING,
Adjustment, Steering Lock Stops
67.Fit Wheel speed sensor.See FUEL SYSTEM,
Repair, Wheel speed sensor - Front 
						

							FRONT AXLE AND FINAL DRIVE
1
SPECIFICATIONS, TORQUE TORQUE VALUES
FRONT AXLE Nm.................................................................. lbf/ft
Hub driving member to hub 65*.............................................. 48*
Brake disc to hub 73............................................................. 55
Stub axle to swivel pin housing 65*........................................ 50*
Brake caliper to swivel pin housing 82.................................. 60
Upper swivel pin to swivel pin housing 65*............................. 48*
Lower swivel pin to swivel pin housing 25*............................. 18*
Oil seal retainer to swivel pin housing 11.............................. 8
Swivel bearing housing to axle case 73*................................ 55*
Differential drive flange to propeller shaft 47......................... 35
Mudshield to bracket lower swivel pin 11.............................. 8
Bevel pinion nut 130................................................................ 95
Draglink to swivel pin arm 40................................................ 30
Panhard rod to axle bracket 88............................................. 65
Radius arm to axle bracket 190.............................................. 140
Radius arm to chassis side member 190................................ 140
Track rod end 40................................................................... 30
Hub adjusting nut 50............................................................. 37
Road wheel nuts 130.............................................................. 95
NOTE: * These bolts to be coated with Loctite 270 prior to assembly. 
						

							STEERING
1
DESCRIPTION AND OPERATION DESCRIPTION
The steering system incorporates a compression joint
in the lower shaft and is designed to collapse on
impact. The misalignment of the upper steering
column with the steering box and the inclusion of two
universal joints, is also designed to prevent the
column moving towards the driver under frontal
impact.
The steering box is located behind the first chassis
cross member and is connected to the road wheel
swivel housing by a drag link and track rod. An
hydraulic damper absorbs shocks in the steering,
caused by road wheel deflections when operating on
rough terrain.Power steering system
The power steering system comprises an hydraulic
pump which is belt driven from the engine and
supplied with fluid from a reservoir that also acts as a
cooler.
The steering box houses a self neutralizing rotary
valve which is part of the worm/valve assy and an
hydraulic piston/rack to assist the mechanical
operation. The rotary valve which is operated by
movement of the steering wheel, directs fluid pressure
to the appropriate side of the hydraulic piston/rack to
provide assistance.
Power steering system
1.Hydraulic pump
2.Fluid reservoir
3.Steering box
4.Upper column
5.Universal joints
6.Lower shaft
7.Compression joint
8.Drag link 
						

							57STEERING
2
DESCRIPTION AND OPERATION
Power steering box components
1.Housing complete with sector shaft bearings
2.Cover plate complete with bearing
3.Sector shaft
4.Hydraulic piston/rack
5.Worm/valve and torsion bar assembly
6.Shims for centralizing worm/valve
7.Ball race - 2 off
8.Teflon seals for valve sleeve - 3 off
9.Bearing adjuster, locknut and seal
10.Worm shaft pressure seal, circlip and dirt
excluder11.Teflon and rubber seal for piston
12.End cover seal and snap ring
13.Adjustment components for piston/rack
14.Hydraulic pipe
15.Bleed screw
16.Sector shaft adjustment lock nut with seal
17.Cover plate bolts - 4 off
18.Cover plate seal
19.Seal, washer and backup seal
20.Circlip and dust cover 
						

							STEERING
3
DESCRIPTION AND OPERATION Rotary valve operation
The rotary valve assembly comprises a worm (1),
valve sleeve (2), input shaft (4) and torsion bar (5).
The valve sleeve is retained inside the worm by a trim
screw (3), and incorporates valve ports in its inner
bore. The input shaft is attached to the steering wheel
via a steering shaft and steering column and
incorporates valve ports in its outer diameter to align
with those in the sleeve. The torsion bar which is
secured to the worm and input shaft with pins (6) at
each end holds the valve ports in neutral alignment
when there is no demand for assistance.No demand for assistance (Valve at neutral)
When there is no demand for assistance, the torsion
bar holds the input shaft and sleeve valve ports in
neutral relationship to one another, allowing equal
pump pressure A to both sides of the piston/rack (9).
Any excess fluid flow from the pump returns to the
reservoir via B.
Rotary valve at neutral 
						

							57STEERING
4
DESCRIPTION AND OPERATION Demand for assistance (Valve misaligned)
When the steering wheel and input shaft is turned,
steering resistance transmitted to the worm causes
the torsion bar to be twisted and the valve ports to be
misaligned for a right or left turn. The misalignment of
the valve ports directs all fluid pressure A to one side
of the piston only and allows displaced fluid B on the
other side.
When demanding maximum assistance, any
excessive fluid output from the pump due to high
pump speed, will circulate through the regulator valve
located in the pump unit, causing the temperature of
the fluid and the pump to rise rapidly.
CAUTION: To avoid excessive fluid
temperatures which could damage the oil
seals, the steering must not be held on full
lock for more than 30 seconds in one minute.
Only when the steering wheel, and hence the demand
for assistance is released, will the torsion bar return
the valve to neutral, allowing the fluid to circulate
through the reservoir where it is cooled.
In the unlikely event of mechanical failure of the
torsion bar, a coarse splined connection (7) between
the input shaft and worm, ensures steering control is
maintained sufficient to allow the vehicle to be
recovered.
Rotary valve misaligned 
						

							STEERING
5
DESCRIPTION AND OPERATION Pump and regulator valve operation
The pump which is belt driven from the engine is an
eccentric roller type and also houses the pressure
regulator and flow control valve. The pressure is
controlled by a spring loaded ball valve (3) which is
housed inside the flow control valve piston (4).
No demand for assistance
High flow through box - Low pressure
With no demand for assistance the rotary valve in the
steering box acts as a pressure relief valve, allowing
fluid A to flow freely through the steering box and
back to the reservoir and pump inlet B.
1.1. Reservoir
2.2. Pump
3.3. Pressure control ball valve and spring
4.4. Flow control valve and spring
5.5. Press fit plug (ball bearing)
6.6. Restrictor
The ball plug (5) is pressed into the valve 4 during
manufacture and determines the opening
pressure of pressure relief valve (3).No demand for assistance
No flow, through box - High pressure
When the steering is turned, the rotary valve
effectively stops all fluid flow through the steering box,
thus causing an increase in pressure A. This
increase in pressure is felt in the flow control valve
spring chamber where, at a pre-determined pressure
the relief valve (3) will open and allow the pressure to
escape. The fall in pressure in the flow control spring
chamber, allows the flow control valve to move to the
right, which in turn allows pump output A to escape
directly into the pump inlet B.
As soon as the steering wheel is released after
making a turn, the system reverts to the free flow
condition and the road wheels are returned to the
straight ahead position by the mechanical steering
geometry.
In the event of any hydraulic failure steering control,
though heavy, will be maintained through the
mechanical components in the steering box.