Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							57STEERING
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OVERHAUL
6.Remove set screw retaining rack pad adjuster.
7.Remove rack adjuster and pad.
8.Remove sector shaft adjuster locknut.
9.Remove four bolts from sector shaft cover.
10.Screw in sector shaft adjuster until cover is
removed.
NOTE: Sealant is applied to hexagon
socket to tamperproof sector shaft
adjuster.
11.Slide out sector shaft.12.Remove piston, a bolt screwed into piston will
assist removal.
13.Remove input shaft dirt excluder.
14.Remove worm adjuster locknut using C wrench
LRT-57-007.
15.Remove worm adjuster using wrench
LRT-57-006.
16.Tap splined end of shaft to free bearing.
17.Remove bearing cup and caged ball bearing
assembly.
18.Remove valve and worm assembly.
19.Remove inner bearing cage, cup and shim
washers. Retain shims for reassembly.
NOTE: Should difficulty be experienced,
warm casing and bearing assembly. Cool
bearing cup using a mandrel and tap
steering box on a bench. 
						

							STEERING
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OVERHAUL Steering box seals
20.Remove circlip and seal from sector shaft
housing bore.
CAUTION: Do not remove sector shaft
bearings from casing. Replacement parts
are not available. If sector shaft bearings
are worn, fit a new steering box.
21.Remove dirt excluder, circlip and seal from input
shaft housing bore.
CAUTION: The use of a seal puller is
recommended to prevent damage to
casing, and possible oil leaks.INSPECTING
Piston
22.Discard all rubber seals and provide
replacements.
NOTE: A rubber seal is fitted behind
plastic ring on rack piston. Discard seal
and plastic ring.
Steering box casing
23.Examine piston bore for scoring and wear.
24.Examine feed tube.
25.Fit a new feed tube if damaged. Tighten union to
20 Nm, 15 lbf ft. 
						

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OVERHAUL Sector shaft assembly
26.Check there is no side play on roller.
27.If side play on roller exists fit a new sector shaft.
28.Check condition of adjuster screw threads.
Check adjuster end float. Fit new adjuster if end
float exceeds 0.15 mm, 0.006 in.
29.Examine bearing areas on shaft for excessive
wear.
30.Examine gear teeth for uneven or excessive
wear.
Sector shaft cover assembly
31.Inspect cover and bearing. If worn or damaged,
fit a new steering box.
Sector shaft adjuster locknut
32.The locknut is also a fluid seal. Fit new nut at
overhaul.Valve and worm assembly33.Examine bearing areas for wear. The areas must
be smooth and not indented.
34.Examine worm track which must be smooth and
not indented.
35.Check for wear on torsion bar assembly pin. No
free movement should exist between input shaft
and torsion bar or between torsion bar and
worm.
NOTE: Any sign of wear makes it essential
to fit new valve and worm assembly.
36.Examine valve rings for cuts, scratches and
grooves. The valve rings should be free to rotate
in grooves. 
						

							STEERING
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OVERHAUL 37.If required, replace all three rings, using ring
expanderLRT-57-019. The expander will not
pass over rings already fitted. Remove rings to
allow access without damaging seal grooves.
38.Warm rings and expander tool to aid assembly.
Fit rings to expander, slide expander over valve
and worm assembly. In turn fit rings to their
grooves. Remove expander, slide valve and
worm assembly into ring compressor
LRT-57-020and allow to cool.
Ball bearing and cage assemblies
39.Examine ball races and cups for wear and
general condition.
40.If ball cage has worn against bearing cup, fit
replacements.
41.Bearing balls must be retained by cage.
42.Bearing and cage repair is carried out by
complete replacement of assembly.Rack thrust pad and adjuster
43.Examine thrust pad for scores.
44.Examine adjuster for wear in pad seat.
45.Fit new sealing ring to rack adjuster.
Rack and piston
46.Examine for excessive wear on rack teeth.
47.Ensure thrust pad bearing surface is free from
scores and wear.
48.Ensure piston outer diameters are free from
burrs and damage.
49.Examine seal and ring groove for scores and
damage.
50.Fit new ring to piston. Warm nylon seal and fit to
piston.
51.Slide piston assembly into cylinder with rack
tube outwards. 
						

							57STEERING
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OVERHAUL Reassemble
NOTE: When fitting replacement oil seals
lubricate with recommended fluid and
ensure absolute cleanliness.
Sector shaft oil seal
52.Fit oil seal, lip side first.
53.Fit extrusion washer.
54.Fit dust seal, lipped side last.
55.Fit circlip.Fitting valve and worm assembly
56.Refit original shims and inner bearing cup. Use
Petroleum Jelly to aid assembly.
NOTE: If original shims are not used, fit
shims of 0.76 mm, 0.030 in thickness.
57.Fit inner cage and bearings assembly.
58.Fit valve and worm assembly.
59.Fit outer cage and bearings assembly.
60.Fit outer bearing cup.
61.Fit new worm adjuster sealing ring. 
						

							STEERING
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OVERHAUL
62.Loosely screw adjuster into casing.
63.Fit locknut, do not tighten.
64.Turn in worm adjuster until end float is almost
eliminated. Ensure bearing cages are seated
correctly.
65.Measure maximum rolling torque of valve and
worm assembly, using a torque wrench and
spline socketLRT-57-025.
66.Turn in worm adjuster while rotating shaft to
increase figure measured in instruction 65. to
0.56 Nm, 0.41 lbf ft.
67.Back off worm adjuster 1/4 turn. Turn in worm
adjuster to increase reading at 14 by 0.21 - 0.34
Nm, 0.15 - 0.25 lbf ft with locknut tight,
100 Nm
74 lbf ft
. Use worm adjusting wrench
LRT-57-006and locknut wrench LRT-57-028.Fitting rack and piston
68.Screw slave bolt into piston to aid assembly.
69.Fit piston and rack so piston is 70 mm, 2.75 in
from outer end of bore.
Fitting sector shaft
70.Fit sector shaft using seal saverLRT-57-021.
Align roller with cut out in casing. Push in sector
shaft while rotating input shaft to allow sector
roller to engage worm. 
						

							57STEERING
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OVERHAUL Fitting rack adjuster
71.Fit rack adjuster and thrust pad to engage rack.
Back off half turn on adjuster.
72.Loosely fit new nylon pad and adjuster set screw
assembly.
Fitting sector shaft cover
73.Fit new sealing ring to cover.
74.Align cover with casing.
75.Screw cover assembly fully on to sector shaft
adjuster screw.76.If necessary back off sector shaft adjuster screw.
Tap cover in place to allow cover to joint fully
with casing.
NOTE: Before tightening fixings, rotate
input shaft to ensure sector shaft roller is
free to move in valve worm. If initial
resistance is left, turn adjuster screw
approximately two turns in a clockwise direction.
77.Fit cover bolts. Tighten to
75 Nm, 55 lbf ft.
Fitting cylinder cover
78.Fit new square section seal to cover.
79.Remove slave bolt fitted at instruction 68. Press
cover into cylinder just to clear retainer ring
groove.
80.Fit retaining ring to groove with one end of ring
positioned 12 mm, 0.472 in from extractor hole. 
						

							STEERING
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OVERHAUL Adjusting sector shaft
NOTE: Refit drop arm and tighten nut
sufficiently to ensure that no backlash
exists between drop arm and sector shaft.
81.To set worm on centre, rotate input shaft to full
inner-lock full right lock for a left hand drive
vehicle, full left lock for a right hand drive
vehicle. Rotate input shaft back towards centre
two full turns.
82.The box is now on centre and can be adjusted.
83.Hold input shaft and rock drop arm to establish
backlash is present. Continue rocking and slowly
turn sector shaft adjusting screw clockwise.
Continue rotating adjuster screw until backlash
has almost been eliminated.
84.Refit locknut and tighten.
NOTE: It is important steering box is
centralised before any adjustments are
made.
85.Check maximum rolling torque one and a quarter
turns either side of centre position, using a
torque wrench and spline socketLRT-57-025.
Rotate adjuster screw to obtain across centre
torque of 0.34 Nm, 0.25 lbf ft plus torque figure
at one and a quarter turns. Tighten adjuster
locknut to
60 Nm, 44 lbf ft.Adjusting rack adjuster.
86.Turn in rack adjuster to increase figure
measured in instruction 34. by 0.23 - 0.34 Nm,
0.17 - 0.25 lbf ft.
The final figure may be less, but must not
exceed 1.35 Nm, 1.0 lbf ft.
87.Lock rack adjuster in position with grub screw.
Tighten to
5 Nm, 4 lbf ft.
Torque peak check
With input shaft rotated from lock to lock, rolling
torque figures should be greatest across centre
position and equally disposed about centre position.
The condition depends on value of shimming fitted
between valve and worm assembly inner bearing cup
and casing. The original shim washer value will give
correct torque peak position unless major components
have been replaced.
88.With input coupling shaft toward the operator,
turn shaft fully counter-clockwise.
89.Check torque figures obtained from lock to lock
using torque wrench and spline socket
LRT-57-025.
90.Check also for equal engagement either side of
centre. 
						

							57STEERING
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OVERHAUL Adjustments
91.Note where greatest figures are recorded
relative to steering position. If greatest figures
are not recorded across centre of travel (steering
straight-ahead), adjust as follows:
If torque peak occursbeforecentre position,addto
shim washer value; if torque peak occursaftercentre
position,subtractfrom shim washer value,
refer to
fitting valve and worm assembly
.
Shim washers are available as follows:
0.03mm, 0.07mm, 0.12mm and 0.24mm
0.001in, 0.003in, 0.004in and 0.008in.
NOTE: Adjustment of 0.07mm, 0.003 in to
shim value will move torque peak area by
1/4 turn on the shaft.
CAUTION: When reshimming valve and
worm, extreme caution must be exercised
to prevent seal damage during
reassembly.
Input shaft oil seal
92.Fit seal, lip side first, into housing. Use seal
saverLRT-57-016and seal installerLRT-57-026.
Note that seal is fitted to a depth of 4.75 - 5.00
mm, 0.19 - 0.20 in from face of box.
93.Secure seal with circlip.
94.Smear inner lip of dirt excluder with grease. Fit
dirt excluder usingLRT-57-027. When fitted
correctly outer shoulder of excluder is 4.00 - 4.50
mm, 0.16 - 0.18 in from face of box, dimension
X.
95.Remove drop arm. Smear inner lip of dirt
excluder with PTFE grease and refit, ensuring
outer lip is flush with casing.
96.With input shaft on centre, align assembly marks
on drop arm and steering box. Fit drop arm to
steering box using a new tab washer. Tighten
nut to
175 Nm, 130 lbf ft,bend over tab.
97.Fit steering box
See Repair, Power Steering
Box
. 
						

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1
SPECIFICATIONS, TORQUE TORQUE VALUES
Nm lbf ft
Drag link to drop arm 40........................................................ 30
Ball joint nuts 40.................................................................... 30
Clamp bolt nuts 14................................................................ 10
Steering column bracket nuts 22........................................... 16
Steering wheel nut 50........................................................... 37
Tie bar to mounting nut 110.................................................... 80
Universal joint pinch bolt 25.................................................. 18
PAS boxAdjuster locknut 60....................................................... 45
Drop arm nut 175........................................................... 130
Sector shaft cover to steering box 75........................... 55
Steering box to chassis 80........................................... 60
Steering box fluid pipes 14mm thread 15..................... 11
Steering box fluid pipes 16mm thread 20..................... 15
Tie bar 80..................................................................... 60
Adjuster grub screw 5................................................ 4
PAS pumpHigh pressure fluid pipe 20.......................................... 15
Power steering pump mounting 35.............................. 25
Pulley bolts, power steering pump 10.......................... 7
Hose clamp 3............................................................. 2
Front clamping bracket bolts 9................................... 7 PAS reservoir
Hose clamp 3............................................................. 2
The following Torque values are for screws and bolts that are not specified on previous page.
METRIC Nm lbf ft
M5 6........................................................................... 4.5
M6 9........................................................................... 7
M8 25........................................................................... 18
M10 45......................................................................... 33
M12 90......................................................................... 65
M14 105......................................................................... 77
M16 180......................................................................... 133
UNC / UNF1/4 9........................................................................... 7
5/16 24......................................................................... 18
3/8 39........................................................................... 29
7/16 78......................................................................... 58
1/2 90........................................................................... 65
5/8 135........................................................................... 100