Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							STEERING
5
REPAIR STEERING COLUMN
Service repair no - 57.40.01
Remove
1.Loosen clip securing air inlet hose to MAF
sensor.
2.Loosen clip securing air inlet hose to plenum
chamber.
3.Remove air inlet hose.
4.Mark relationship of top universal joint to
steering column and shaft.
5.Remove 2 bolts from top universal joint.
6.Remove steering shaft top universal joint.
7.Remove centre pad from steering wheel.
8.Remove nut securing steering wheel to column
and collect washer.
9.Using toolsLRT-57-014andLRT-57-015,
remove steering wheel from column.
10.Disconnect battery negative lead.
11.Remove instrument panel.
See
INSTRUMENTS, Repair, instrument panel
12.Remove 7 screws securing nacelle to steering
column.
13.Remove top half of nacelle.
14.Release bottom half of nacelle from indicator
and light stalk grommets and remove.
15.Remove bolt securing steering column to upper
mounting bracket. 
						

							57STEERING
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REPAIR
16.Remove 2 lower bolts securing steering column
to body.
17.Remove 2 upper clamping bolts and collect
clamp and rubber.
18.Release harness from clip on column upper
mounting bracket.
19.Release clip from column upper mounting
bracket.
20.Remove 4 bolts securing column upper
mounting bracket.
21.Remove upper mounting bracket.
22.Disconnect 3 multiplugs from rear of switch
pack.
23.Loosen screw and remove switch pack.
24.Disconnect multiplug and 6 Lucars from ignition
switch.
NOTE: Note the positions of the Lucar
connections to the ignition switch.
25.Drill out 2 shear bolts securing ignition barrel to
steering column.
26.Remove ignition barrel and collect washers.
27.Remove brake pedal.
See BRAKES, Repair,
brake pedal
28.Remove steering column and upper mounting
bracket from vehicle.
NOTE: The steering column is a non
serviceable component and can only be
replaced as a complete assembly.
Refit
29.Manoeuvre steering column into position in
vehicle.
30.Fit brake pedal.
See BRAKES, Repair, brake
pedal
31.Position ignition barrel to steering column and
rotate inner shaft to line up slot with barrel
plunger.
32.Position barrel clamp to steering column and
secure with shear bolts. Evenly tighten bolts, but
do not shear them.
33.Temporarily fit steering wheel and operate
switch and lock mechanism several times to
ensure it functions correctly. 
						

							STEERING
7
REPAIR 34.Fully tighten ignition barrel bolts until heads
shear.
35.Connect multiplug and Lucars to ignition barrel.
36.Fit switch pack to steering column and secure
with screw.
37.Connect multiplugs to rear of switch pack.
38.Position column upper mounting bracket and
tighten bolts to
22 Nm, 16 lbf ft.
39.Fit clip to mounting bracket and secure harness.
40.Fit rubber and clamp to upper steering column.
41.Fit clamp bolts and tighten to
22 Nm, 16 lbf ft.
42.Fit lower steering column bolts and tighten to22
Nm, 16 lbf ft.
43.Fit bolt securing column to upper mounting
bracket and tighten to
22 Nm, 16 lbf ft.
44.Fit lower half of steering column nacelle and
secure to stalk grommets.
45.Fit top half of steering column nacelle.
46.Fit and tighten screws securing nacelle to
steering column.
47.Fit instrument panel.
See INSTRUMENTS,
Repair, instrument panel
48.Reconnect battery negative lead.
49.Turn indicator cancelling ring so that slots are
vertical and lug with arrow points to the left.
50.Fit steering wheel with finisher attachment lug at
bottom, ensuring indicator cancelling forks locate
in ring slots.
51.Fit new washer and tighten securing nut to
50
Nm, 37 lbf ft.
52.Fit centre pad to steering wheel.
53.With steering lock engaged, and wheels in
straight ahead position, align assembly marks
and connect steering shaft universal joint to
steering column.
54.Tighten universal joint pinch bolts to
25 Nm, 18
lbf ft.
55.Fit air inlet hose between plenum chamber and
MAF sensor and tighten clips.STEERING LOWER SHAFT
Service repair no - 57.40.25
Remove
1.Set road wheels and steering wheel in straight
ahead position.
2.Loosen clip securing air inlet hose to MAF
sensor.
3.Loosen clip securing air inlet hose to Plenum
chamber.
4.Remove air inlet hose.
5.Mark relationship of steering column inner shaft
to top universal joint.
6.Remove 2 bolts from top universal joint.
7.Remove lower bolt from bottom universal joint.
8.Loosen upper bolt from bottom universal joint.
9.Remove steering shaft and collect universal
joints.
10.Inspect universal joints for wear and excessive
play. Renew if necessary.
11.Inspect universal joints for stiffness. Lubricate if
necessary. 
						

							57STEERING
8
REPAIR Refit
12.Fit universal joints to steering shaft so pinch
bolts line up with flats on shaft.
13.Fit steering shaft assembly to steering column
and steering box.
14.Align bolt holes with grooves in splines. Fit pinch
bolts and tighten to
25 Nm, 18 lbf ft.
15.Fit air inlet hose between plenum chamber and
MAF sensor.
16.Tighten clips securing hose to plenum chamber
and MAF sensor.DROP ARM
Service repair no - 57.50.14
Remove
1.Raise vehicle on a ramp [hoist].
2.Remove bolt securing steering damper to drag
link.
3.Disconnect steering damper from drag link.
4.Remove split pin from castellated nut securing
drag link to drop arm.
5.Remove castellated nut securing drag link to
drop arm.
6.Using special toolLRT-57-018, disconnect drag
link from drop arm. 
						

							STEERING
9
REPAIR
7.Mark relationship between drop arm and
steering box for reassembly.
8.Bend back tabs on drop arm locking washer.
9.Loosen nut securing drop arm to steering box
but do not remove.
10.Use special toolLRT-57-012to release drop arm
from steering box spline.
11.Remove nut and discard locking washer.
12.Remove drop arm.
Refit
13.Centralise steering box.
See Adjustment,
power steering box - centralise
14.Align reassembly marks and fit drop arm onto
steering box splines.
15.Fit new locking washer and retaining nut to
secure drop arm to steering box. Tighten nut to
175 Nm, 130 lbf ft.
16.Bend over locking washer.
17.Fit drag link to drop arm and tighten castellated
nut to
40 Nm, 30 lbf ft.
18.Fit new split pin to castellated nut.
19.Fit steering damper to drag link.
20.Fit and tighten bolt securing steering damper to
drag link.
21.Lower vehicle.TRACK ROD
Service repair no - 57.55.09
Remove
1.Raise vehicle on a ramp [hoist].
2.Centralise steering.
See Adjustment, power
steering box - centralise
3.Remove 2 bolts securing track rod protection
bracket to differential housing.
4.Remove track rod protection bracket. 
						

							57STEERING
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REPAIR
5.Remove 2 split pins from castellated nuts
securing track rod to swivel hubs.
6.Remove 2 castellated nuts securing track rod to
swivel hubs.
7.Using special toolLRT-57-018, release track rod
ball joints from swivel hubs.
8.Remove track rod.
Do not carry out further dismantling if component
is removed for access only.
9.Loosen 2 clamp bolts securing linkages to track
rod.
10.Remove linkages.
11.Fit new linkages to track rod and loosely tighten
clamp bolts.
12.Screw in linkages to full extent of threads and
fully tighten clamp bolts.Refit
CAUTION: A track rod that is damaged or
bent must be renewed. DO NOT attempt to
repair or straighten it.
13.Fit track rod and connect to swivel hubs.
14.Fit and tighten castellated nuts to
40 Nm, 30 lbf
ft.
15.Fit new split pins to castellated nuts.
16.Fit track rod protection bracket to differential
housing and tighten bolts.
17.Check wheel alignment.
See Adjustment,
front wheel alignment
18.Lower vehicle. 
						

							STEERING
11
REPAIR STEERING DAMPER
Service repair no - 57.55.21
Remove
1.Raise vehicle on a ramp [hoist].
2.Remove 2 nuts securing steering damper to
chassis member and collect washer.
3.Remove nut and bolt securing steering damper
to drag link.
4.Release steering damper from drag link and
chassis member and remove.
Refit
5.Position damper to chassis member and drag
link.
6.Fit bolt and new nut securing damper to drag link
and tighten.
7.Fit washer and nuts securing steering damper to
chassis and tighten.
8.Lower vehicle. 
						

							57STEERING
12
REPAIR DRAG LINK AND DRAG LINK ENDS
Service repair no - 57.55.17
Remove
1.Park vehicle on level ground and chock rear
wheels.
2.Set road wheels in straight ahead position.
3.Raise vehicle and fit axle stands or use a ramp.
4.Remove front road wheel.
5.Disconnect steering damper at drag link bracket.6.Remove split pin and castellated nut securing
drag link ball joints to swivel housing arms.
7.Disconnect drag link ball joints using
LRT-57-018.
8.Remove drag link.
Remove drag link ends
9.Slacken clamp bolts.
10.Unscrew ball joints and remove from drag link.
11.Clean internal threads of drag link.
Refit drag link ends
12.Fit new ends to drag link and loosely fit clamp
bolts.
13.Set ball joints to drag link measurement to 28,5
mm.
14.Adjust ball pin centres to nominal length of 924
mm, this length is adjusted during refit. 
						

							STEERING
13
REPAIR 15.Centralise steering box
See Adjustment,
Centralise steering box .
16.Align steering wheel, if necessary.
Refit drag link
CAUTION: A drag link that is damaged or
bent must be renewed. DO NOT attempt to
repair it.
17.Fit drag link to swivel housing arms and tighten
nuts to
40 Nm (30 lbf/ft).Fit new split pins.
18.Ensure full steering travel is obtained between
lock stops
See Adjustment, Steering lock
stops.
Adjust drag link length to suit.
19.Tap ball joints in direction shown so both pins
are in same angular plane.
20.Tighten clamp bolts to
14 Nm, 10 lbf/ft.
21.Refit road wheel and remove axle stands or
vehicle from ramp.
22.Road test vehicle.
23.If driving straight ahead and steering wheel is
offset by 0°±5°in either direction, correct by
adjusting drag link length.
WARNING: To correct steering wheel
deviations greater than±5°remove and
reposition steering wheel
See Steering
wheel. 
						

							STEERING
1
OVERHAUL POWER STEERING BOX
Service repair no - 57.10.07
WARNING: Wear safety glasses while
removing and refitting circlips and
retaining ring.
CAUTION: Absolute cleanliness is
essential when overhauling the power
steering box.
1.Remove steering box from vehicle.See Repair,
Power Steering Box
. Mark drop arm and
steering box for realignment on assembly.
Remove drop arm using extractorLRT-57-012.
Loosen drop arm securing nut, but do not
remove before using extractor. Remove dirt
excluder from output shaft.
2.Drain oil, remove blanking plugs and bleed
screw. Hold steering box over drain tin, turn
input shaft from lock to lock, until oil is drained.
Refit bleed screw.
3.Rotate retainer ring until one end is 12 mm from
extractor hole. Using a drift through hole in
cylinder, lift retaining ring from groove in cylinder
bore.
4.Remove retainer ring, using a screwdriver.
5.Turn input shaft left lock on LH drive, right lock
on RH drive, until piston pushes out cover. Turn
input shaft fully in opposite direction, applying
pressure to piston.