Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual
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STEERING 1 FAULT DIAGNOSIS INSUFFICIENT POWER ASSISTANCE 1.Is fluid level correct? YES - go to 3. NO - Fill/bleed sytem 2.Is problem a leak? YES - Diagnose See Power Steering Fluid Leaks . NO - continue 3.Is drive belt tension correct? YES - go to 5. NO - retension See ELECTRICAL, Repair, Auxiliary drive belt 4.Is problem resolved? YES - end NO - continue 5.Carry out pressure test at idle and 1000 rev/min. See Power Steering System - Test. 6.Is correct pressure achieved? YES - steering box defective Not at any speed go to 9. Not at idle go to 7. 7.Is idle speed correct? YES-Goto8. NO - Correct idle speed - See FUEL SYSTEM, Adjustment, Engine tuning . 8.Is problem resolved? YES - end NO - go to 9. 9.Bypass steering box using adaptor tap LRT-57-001 10.Is correct pressure obtained? YES - defective steering box NO - defective steering pump CAUTION: Do not hold steering wheel on full lock for more than 30 seconds in any one minute to avoid overheating fluid and possibly damaging seals. NOTE: 1. Excessive pressure in the system is almost always caused by a faulty relief valve in the PAS pump. NOTE: 2. Insufficient pressure in the system is usually caused by low fluid level or PAS pump drive belt slip, or one of the following: PAS system leaks, faulty PAS pump relief valve, fault in steering box valve and worm assembly, leak at piston in steering box, worn components in PAS pump or box.
57STEERING 2 FAULT DIAGNOSIS POWER STEERING SYSTEM - TEST NOTE: If steering lacks power assistance. Check pressure of hydraulic pump before fitting new components. Use fault diagnosis chart to assist in tracing faults. A. Steering box. B. Steering pump. C. Existing hose, steering box to pump. D. Hose LRT-57-030. E. Test adaptorLRT-57-001. F. Pressure gaugeLRT-57-005. G. Thread adaptorLRT-57-004. H. Thread adaptorLRT-57-022.Procedure 1.A hydraulic pressure gauge and test adaptor is used to test power steering system. This gauge is able to measure 140 kgf/cm 2, 2000 lbf/in2. The maximum power steering system pressure is 77 kgf/cm 2, 1100 lbf/in2. 2.Some fault conditions of hydraulic pump may obtain pressures up to 105 kgf/cm 2, 1250 lbf/in2. Pressure on gauge is same pressure being exerted upon steering wheel. When testing, turn steering wheel gradually while reading pressure gauge. 3.Check and maintain maximum fluid level of reservoir. 4.Examine power steering units and connections for leaks. All leaks must be rectified before attempting to test the system. 5.Check steering pump drive belt tension See ENGINE, Repair, Drive Belt . 6.Assemble test equipment and fit to vehicle, as shown in RR3959M. 7.Open tap of adaptor. 8.Bleed system, take care not to overload pressure gauge. 9.With system in good condition, pressures should be: (A) Steering wheel held on full lock and engine running at 1,000 rev/min, 70 to 77 kgf/cm 2, 1000 to 2000 lbf/in2. (B) Steering wheel held on full lock and engine idling, 28 kgf/cm 2, 400 lbf/in2. Checks should be carried out on both full lock positions. CAUTION: Do not maintain this pressure for more than 30 seconds in any one minute to avoid overheating fluid and possibly damaging seals. 10.Release steering wheel and with engine idling. Pressure should read below 7 kgf/cm 2, 100 lbf/in2. 11.If pressures differ to those given a fault exists. 12.To determine if fault is steering box or pump. Close adaptor tap for a maximum five seconds. 13.If gauge does not register specified pressure, pump is faulty. 14.Fit a new pump, bleed system and repeat test. If low pressure or a substantial imbalance exists, fault is in steering box valve and worm assembly.
STEERING 3 FAULT DIAGNOSIS STEERING DAMPER The power steering system, as well as reducing the effort required to manoeuvre the vehicle when parking, also helps to dampen any deflections of the road wheels, being transmitted back to the steering wheel. When operating the vehicle off road, the road wheels are often deflected by ruts and boulders causing the steering wheel to turn left and right. This phenomenon is known as steering kickback. To subdue the effects of steering kickback, a hydraulic damper is fitted in the steering linkage between the track rod and the differential casing. The damper, which offers the same resistance in extension and compression, is sealed for life. Steering damper check Check the condition operation of the hydraulic steering damper as follows: Check procedure 1.Inspect damper for casing damage or leaks. 2.Clamp one end of the damper horizontally in a vice using soft jaws. Compress and extend the unit by hand. Resistance should be equal in both directions. 3.If it is felt that the unit is outside acceptable limits, fit a new steering damperSTEERING FAULTS Symptom:- Excessive kickback through steering wheel - when driven on rough terrain. 1.Is the steering damper in good working order? See Steering Damper. NO - Renew unitSee Repair, Steering Damper. YES - Continue. 2.Is there any looseness or free play in the steering ball joints and linkage? YES - See Steering Linkage Inspect. NO - Continue. 3.Is there any looseness or worn bushes in front suspension? YES - See FRONT SUSPENSION, Repair, Radius Arm. NOTE: When replacing suspension bushes ALL bushes and fixings must be replaced. NO - Continue. 4.Is the steering exceptionally light/sensitive when driven on good road surface? YES - See fault symptom -Steering excessively light/sensitive and freeplay at steering wheel. NO - Suspect axle swivel resistance. 5.Check the resistance of the axle swivels See FRONT AXLE AND FINAL DRIVE, Overhaul, Front Stub Axle, Constant Velocity Joint and Swivel Pin Housing.
57STEERING 4 FAULT DIAGNOSIS Symptom:- Fluid leaks from steering box seals. CAUTION: The steering wheel must not be held on full lock for more than 30 seconds in one minute, as this may overheat the fluid and cause damage to the oil seals. 1.Check fluid level See Repair, Power Steering Fluid Reservoir. Check fluid pressureSee Power Steering System - Test. 2.Is pressure high? YES - Renew pump See Repair, Power steering Pump. If oil seal leaks persist after renewing the pump See Overhaul, Power Steering Box. NO -See Overhaul, Power Steering Box. Symptom:- Insufficient power assistance - castor return action normal. 1.Are tyres correct type and pressure? NO - See GENERAL SPECIFICATION DATA, Information, Wheels and Tyres. YES - Continue. 2.Is fluid level correct? NO - Check fluid level See Repair, Power Steering Fluid Reservoir. YES - Check system for air locksSee Repair, Power Steering System - Bleed. 3.Is pressure correct? NO - Check fluid pressure See Power Steering System - Test. If pressure is not correct after bleeding the system, renew pump See Repair, Power Steering Pump. YES -See Overhaul, Power Steering Box. Symptom:- Steering heavy - stiff, poor castor return action. 1.Are tyres correct type and pressure? NO - See GENERAL SPECIFICATION DATA, Information, Wheels and Tyres. YES - Check universal joints for seizure and correct alignment See Repair, Lower Steering Shaft and Universal Joints . Check power steering box adjustments See Overhaul, Power Steering Box. 2.Is the power assistance satisfactory? NO - See fault symptomInsufficient assistance, (castor return action normal). YES - Disconnect drag link from drop arm and check steering column and box for stiffness See Repair, Drag Link and Drag Link Ends. 3.Is the steering stiff with the drag link disconnected? NO - Check steering ball joints for seizure and axle swivels lubrication and resistance See Repair, Drag Link and Drag Link Ends ,See FRONT AXLE AND FINAL DRIVE, Overhaul, Front Stub Axle, Constant Velocity Joint and Swivel Pin Housing. YES - Disconnect the lower steering shaft and check the column and box for stiffness See Repair, Lower Steering Shaft and Universal Joints. 4.Is the steering column stiff to turn when disconnected from the box? NO - Remove and overhaul box See Overhaul, Power Steering Box. YES - Adjust steering columnSee Stiff Steering Checklist.
STEERING 5 FAULT DIAGNOSIS Symptom :- Steering excessively light/sensitive. Excessive freeplay at steering wheel. 1.Are steering box adjustments correct? NO - See Adjustment, Power Steering Box. WARNING: Adjustments of steering box should not be required while in warranty period. If box is within warranty, it must be returned to manufacturer. No attempt must be made to introduce backlash. YES - Suspect worn panhard rod or radius arm bushes. Check condition of ball joints and the lower steering column shaft universal joints for wear See Repair, Lower Steering Shaft and Universal Joints. Symptom :- Steering vibration, road wheel shimmy - wobble. Vibration through the steering linkage powerful enough to induce high frequency oscillation of the steering wheel, is generally caused by out of balance road wheels. However there are a number of other possible causes of this symptom which if severe, may be described as shimmy or wobble. Regardless of the terminology used by the owner/driver to describe the symptoms, the following diagnostic checks should be carried out in the order presented. 1.Check the tyres and balance of the road wheels See GENERAL SPECIFICATION DATA, Information, Wheels and Tyres ,See WHEELS AND TYRES, Fault diagnosis, Fault - Symptoms See WHEELS AND TYRES, Repair, Wheel Balancing. 2.Check the steering hydraulic damper function See Steering Damper. 3.Check steering column universal joints for wear and correct alignment See Repair, Lower Steering Shaft and Universal Joints. 4.Check steering linkage ball joints for wear, correct alignment and security, including steering box and tie rod, See Steering Linkage Inspect. 5.Check all front suspension rubbers for wear. Check all fixing torques, including radius arm bushes, panhard rod and anti-roll [sway] bar See FRONT SUSPENSION, Repair, Panhard Rod, See FRONT SUSPENSION, Repair, Radius Arm, See FRONT SUSPENSION, Repair, Anti-Roll Bar Assembly, See FRONT SUSPENSION, Repair, Front Shock Absorber. 6.Fit new radius arm bushes using NTC 6860. Fit new nuts, bolts and washers. 7.If problem persists fit damper kit STC 241 (2 off front) and STC 1474 (2 off rear). Road test vehicle. 8.Check the power steering box adjustments and operation See Overhaul, Power Steering Box. 9.Check the hub bearing end floats and determine the condition of the hub bearings as applicable See FRONT AXLE AND FINAL DRIVE, Repair, Front Hub Assembly. 10.Check the resistance and condition of the swivels See FRONT AXLE AND FINAL DRIVE, Description and operation, Description. If problem is not diagnosed: Repeat checks starting at 1. 11.Carry out a full steering geometry check See INTRODUCTION, Information, Steering.
57STEERING 6 FAULT DIAGNOSIS STEERING STABILITY AND VEER UNDER BRAKING Possible cause: Incorrectly set, swivel pin bearing preload. Remedy. 1.Follow instructions to overhaul front stub axle, constant velocity joint and swivel pin See FRONT AXLE AND FINAL DRIVE, Overhaul, Front Stub Axle, Constant Velocity Joint and Swivel Pin Housing. 1. GENERAL STEERING 1.Carry out visual and safety checks See Visual and Safety Checks. 2.Road test vehicleSee Road Test Procedure . 3.Is problem resolved? YES - end NO - continue 4.Is problem stiff steering? YES - See Stiff Steering Checklist . NO-Goto6. 5.Is problem resolved? YES - end NO - go to 8. 6.Is problem steering niggle ? YES - Replace radius arm bushes, arm and axle See FRONT SUSPENSION, Repair, Radius Arm. NO - go to 8. 7.Is problem resolved? YES - end NO - continue. 8.Centralise steering box See Adjustment, Centralise Steering Box. 9.Is problem resolved? YES - end NO - continue. 10.Check, adjust if necessary, steering geometry. 11.Is problem resolved? YES - end NO - continue. 12.Categorise the remaining problems into one or more of the following descriptions: See 2. Steering Veer . See 3. Veer Under Braking . See 4. Directional Stability .
STEERING 7 FAULT DIAGNOSIS 2. STEERING VEER From 1. GENERAL STEERING: 1.Vehicle veers, not under braking, swap front tyres side to side. 2.Is problem resolved? YES - end NO - continue. 3.Does vehicle now veer in other direction? YES - fit new tyres NO - continue. 4.Recentralise steering box See Adjustment, Centralise Steering Box. 5.Is problem resolved? YES - end NO - contact local technical office.3. VEER UNDER BRAKING From 1. GENERAL STEERING: 1.Vehicle veers under braking, bleed brake system. 2.Is problem resolved? YES - end NO - continue. 3.Check brake pads for glazing, and discs, axles etc for contamination. 4.Is problem resolved? YES - end NO - continue. 5.Check brake lines and hoses for deterioration. Replace as necessary. 6.Is problem resolved? YES - end NO - continue. 7.Contact Technical Support Office.
57STEERING 8 FAULT DIAGNOSIS 4. DIRECTIONAL STABILITY From 1. GENERAL STEERING: 1.Is directional stability concern when vehicle is towing? YES - Check towing/vehicle loading parameters in Owners Handbook. NO - go to 3. 2.Is problem resolved? YES - end NO - continue. 3.Check condition of rear trailing link/chassis bushes. 4.Is problem resolved? YES - end NO - continue. 5.Check condition of front and rear shock absorbers. If in doubt change units in pairs, side to side. 6.Is problem resolved? YES - end NO - continue. 7.Check steering damper See Steering Damper. 8.Is problem resolved? YES - end NO - continue. 9.Check wheel balance 10.Is problem resolved? YES - end NO - contact local technical office.POWER STEERING FLUID LEAKS 1.Is fluid level correct? YES - go to 3. NO - Refill or drain to correct level. Bleed system, check for leaks See Repair, Power Steering System - Bleed. 2.Is problem resolved? YES - end NO - continue. 3.Are hoses or joints leaking? Check on full lock with engine at 2000 rev/min. YES - loosen and retorque joints. NO - go to 6. 4.Does leak remain? YES - change PAS pipe. NO - end. 5.Does leak remain? YES - suspect seal in component. Check and replace as necessary. NO - end. 6.Is oil escaping from filler cap? YES - bleed system See Repair, Power Steering System - Bleed. NO - go to 8. 7.Is oil still escaping from filler cap? YES - go back to 1. NO - end. 8.Is oil leaking from PAS pump? YES - go to 10. NO - continue. 9.Is oil leaking from PAS box? YES - go to 10. NO - end. 10.Clean unit, add tracer dye to system. Retest 11.Is oil still leaking? YES - establish leak point. Repair or replace unit as necessary. NO - end.
STEERING 9 FAULT DIAGNOSIS POWER STEERING SYSTEM - EXCESSIVE NOISE 1.Is fluid level correct? YES - go to 3. NO - Refill or drain to correct level. Bleed system, check for leaks See Repair, Power Steering System - Bleed. 2.Is problem resolved? YES - end NO - continue. 3.Is pressure hose from pump to box touching body in a hard foul condition? YES - reroute hose away from body. NO - go to 5. 4.Does noise remain? YES - continue. NO - end. 5.Is noise a whistle or hiss on full lock? YES - noise is not a fault unless excessive. Compare with other vehicles NO - go to 8. 6.Is noise excessive? YES - continue. NO - end. 7.Change steering box and/or pump. 8.Is noise a squeal on full lock? YES - checkdrive belt tension See ELECTRICAL, Repair, Auxiliary drive Belt. NO - go to 10. 9.Does squeal remain? YES - drive belt contaminated, change belt See ELECTRICAL, Repair, Auxiliary drive belt. NO - end. 10.Is noise a continuous moan? YES - bleed PAS system See Repair, Power Steering System - Bleed. NO - go to 13. 11.Does moan remain? YES - do figure 8 manoeuvres. NO - end. 12.Does moan remain? YES - continue NO - end.13.Is noise an intermittent grunt? YES - See Power Steering System - Grunt. NO - continue. 14.Is it a clunking noise? YES - check drive belt tension See ELECTRICAL, Repair, Auxiliary drive Belt. NO - contact local technical office. 15.Does noise remain? YES - Suspect suspension or drive train. NO - end. POWER STEERING SYSTEM - GRUNT Steering box grunts intermittently when turning from lock to lock: 1.Is fluid level correct? YES - go to 3. NO - refill or drain to correct level. Bleed system, check for leaks See Repair, Power Steering System - Bleed. 2.Does grunt remain? YES - continue NO - end. 3.Is correct low pressure hose, steering box to reservoir fitted? YES - go to 5. NO - Fit correct hose. 4.Does grunt remain? YES - continue NO - end. 5.Purge box by doing figure 8 manoeuvres e.g. on car park, followed by 10 minutes normal road use. 6.Does grunt remain? YES - Contact local technical office NO - end.
57STEERING 10 FAULT DIAGNOSIS VISUAL AND SAFETY CHECKS WARNING: Before taking vehicle out on the public highway for road test, it is important that the following basic visual checks are carried out to ensure that the vehicle complies with legal requirements. Tyres and wheel rims 1.Check and adjust tyre pressures See GENERAL SPECIFICATION DATA, Information, Tyre Pressures. Note that this information refers to standard tyres fitted as original equipment. 2.Check condition of tyres. Inspect for signs of uneven wear, damage and feathering. Check tread depth. 3.Ensure that the tyre make, type and general condition are common across each axle. 4.Check wheel rims for signs of damage and excessive run out. 5.Carry out road test See Road Test Procedure. ROAD TEST PROCEDURE General steering/handling problems can usually be classified into one of the categories listed and ARE GENERALLY RELATED TO THE AGE, CONDITION AND USE OF THE VEHICLE. WARNING: Ensure that all road tests are conducted by suitably qualified drivers in a safe and legal manner, and where local traffic conditions allow. 1.Carry out visual and safety checks See Visual and Safety Checks . Confirm general nature of complaint with customer, simulating where possible the conditions under which the problem occurs. Carry out following road test procedure to establish the problem.2.Steering load assessment - drive at 15 km/h, 10 mph. Put 90°turn input into steering wheel, check self centering. The self centering should be equal on each lock but not necessarily return to exactly straight ahead without assistance from the driver. 3.Steering assessment - drive at 65 km/h, 40 mph on a staight FLAT road (no camber), check for steering veer. The vehicle should follow a straight path with NO tendency to follow a curved path. If vehicle veers towards the kerb, vehicle may be camber sensitive. A small amount of veer in direction of camber is acceptable. 4.Directional stability assessment - drive at 110 km/h, 70 mph or maximum legal speed on a straight flat road. Carry out a normal lane change. Vehicle should quickly settle into a new straight path. 5.Braking assessment (medium effort) - drive at 95 km/h (60 mph) on a straight flat road. Apply steady medium braking effort, noting any tendency to veer. Carry out brake test three times, if a veer is consistently noted carry out a braking efficiency test on a rolling road. 6.Braking assessment (full effort) - drive at 95 km/h, 60 mph on a straight flat road. Apply full braking effort, noting any tendency to veer. Carry out brake test 3 times, if a veer is consistently noted carry out a braking efficiency test on a rolling road. If the symptom described by the customer is stiff steering or steering niggle, carry out stiff steering procedure See Stiff Steering Checklist. If not, proceed with basic checks and adjustments See Visual Check and Basic Adjustments .