Land Rover Defender 90 Workshop 2nd Edition Nas Rover Manual

							FRONT SUSPENSION
1
DESCRIPTION AND OPERATION DESCRIPTION
The front suspension design allows maximum wheel
travel and axle articulation providing good ground
clearance without loss of traction or directional
stability. A wheel speed sensor is attached to each
swivel housing with a reluctor ring on the constant
velocity joints. The input from the wheel sensors are
used by the engine management ECM for Off-road
detection.
Long radius arms are fitted to the front axle and
provide maximum axle articulation which is vital for off
road performance. The radius arms are secured to
fabricated mounting brackets welded to the front axle.
Flexible rubber bushes are used on a stem end joint
to secure the rear of the radius arms to mountings on
the chassis cross member.
A panhard rod, which ensures that the front axle
remains centrally located, is fitted transversely andalso uses ferrule rubber bush mountings at both axle
and chassis locations.
Two rubber bearing bushes, with retaining straps,
secure the rear of the anti-roll bar to the chassis
mountings, while bushed links support the front of the
bar to the front axle.
Conventional long travel coil springs and hydraulic
shock absorbers are used to control body movement
in all conditions. The shock absorbers are secured to
fabricated towers which are bolted to the chassis. The
upper and lower fixings use a single location stud with
flexible rubber bushes, support washers and securing
nuts. Retaining plates are used to secure the coil
springs to the fabricated towers and axle mountings.
Rubber bump stops are fitted underneath the chassis,
adjacent to the front road springs, and prevent
possible damage that could occur should there be
excessive axle to chassis movement.
Front suspension
1.Panhard rod
2.Radius arms
3.Coil springs4.Shock absorber
5.Anti-roll [sway] bar 
						

							FRONT SUSPENSION
1
REPAIR SELF LOCKING NUTS
WARNING: Where self locking nuts are
removed, they must be replaced with new
nuts of same specification.ANTI-ROLL [SWAY] BAR
Service repair no - 60.10.01
Remove
1.Raise vehicle on a ramp [hoist].
2.Mark anti-roll [sway] bar rubber bushes for
reassembly.
3.Remove 4 nuts and bolts securing anti-roll
[sway] bar to mounting brackets.
4.Remove 2 nuts and bolts securing anti-roll
[sway] bar to ball joint links.
5.Remove anti-roll [sway] bar.
6.Remove rubber bushes from anti-roll [sway] bar.
Refit
7.Fit bushes to anti-roll [sway] bar. Ensure split in
bushes points towards axle on RH side, and
away from axle on LH side.
8.Position anti-roll [sway] bar and loosely fit nuts
and bolts to mounting brackets.
NOTE: Angled sides of bar should point
downwards.
9.Using new nuts, fit anti-roll [sway] bar to ball joint
links. Tighten to
68 Nm, 50 lbf ft.
10.Tighten nuts and bolts securing anti-roll [sway]
bar to mounting brackets to
30 Nm, 22 lbf ft.
11.Lower vehicle. 
						

							60FRONT SUSPENSION
2
REPAIR ANTI-ROLL [SWAY] BAR BALL JOINT LINKS
Service repair no - 60.10.04
Remove
1.Raise vehicle on a ramp [hoist].
2.Remove 2 nuts and bolts securing ball joint links
to anti-roll [sway] bar and collect washers and
rubber bushes.
3.Release ball joints using special tool
LRT-57-018.
4.Remove 2 split pins from castellated nuts.
5.Remove 2 castellated nuts.
6.Remove ball joint links.
Refit
7.Fit ball joint links, ensuring they point upwards.
8.Fit castellated nuts and tighten to
40 Nm, 30 lbf
ft.
9.Fit split pins to castellated nuts.
10.Align anti-roll [sway] bar to ball joint links.
11.Fit bolts, washers, rubber bushes, and new lock
nuts securing anti-roll [sway] bar to ball joint
links. Tighten bolts to
68 Nm, 50 lbf ft.
12.Lower vehicle.PANHARD ROD
Service repair no - 60.10.07
Remove
1.Raise vehicle on a ramp [hoist].
2.Remove bolt securing Panhard rod to mounting
arm and collect nut
3.Remove bolt securing Panhard rod to axle
bracket and collect nut.
4.Remove Panhard rod.
Do not carry out further dismantling if component
is removed for access only.
5.Press out flexible bushes.
CAUTION: Ensure pressure is exerted on
outer edge of bush, not rubber inner.
6.Fit replacement bushes.
Refit
7.Position Panhard rod to axle bracket and
mounting arm.
8.Fit nut and bolt securing Panhard rod to axle
bracket and tighten to
88 Nm, 65 lbf ft.
9.Fit nut and bolt securing Panhard rod to
mounting arm and tighten to
88 Nm, 65 lbf ft.
10.Lower vehicle. 
						

							FRONT SUSPENSION
3
REPAIR RADIUS ARM
Service repair no - 60.10.16
Remove
1.Raise front of vehicle.
WARNING: Support on safety stands.
2.Remove road wheel(s).
3.Raise front of vehicle and support axle.
4.Remove nut securing radius arm to chassis side
member and collect washer and rubber bush.
5.Remove 2 bolts securing radius arm to axle and
collect nuts.
6.Remove split [cotter] pin from castellated nut
securing track rod to swivel hub.
7.Remove castellated nut securing track rod to
swivel hub.
8.Using special toolLRT-57-018release track rod
from swivel hub.
9.Move track rod aside.
10.Lower front of radius arm to clear axle and
remove from vehicle.
Do not carry out further dismantling if component
is removed for access only.
11.Press out bushes from radius arm.
CAUTION: Ensure pressure is exerted on
outer edge of bushes, and not rubber
inner.
12.Press in replacement bushes.
Refit
13.Position radius arm to vehicle.
14.Loosely fit bolts securing radius arm to axle.
15.Connect track rod to swivel hub.
16.Fit and tighten castellated nut securing track rod
to swivel hub to
40 Nm, 30 lbf ft.
17.Fit new split [cotter] pin to castellated nut.
18.Tighten nuts securing radius arm to axle to
197
Nm, 145 lbf ft.
19.Fit rubber bush and washer to radius arm.
20.Fit and tighten nut securing radius arm to
chassis member to
175 Nm, 130 lbf ft.
21.Remove jack from under axle.
22.Fit road wheel.
23.Remove stand(s) and lower vehicle. 
						

							60FRONT SUSPENSION
4
REPAIR FRONT SHOCK ABSORBER
Service repair no - 60.30.02.
Remove
1.Loosen road wheel retaining nuts.
2.Support chassis on stands and remove road
wheel.
3.Support axle weight with jack.
4.Remove shock absorber lower fixing and
withdraw cupwasher, rubber bush and seating
washer.
5.Remove four shock absorber bracket fixings.
6.Withdraw shock absorber and bracket complete.
7.Withdraw lower seating washer, rubber bush and
cupwasher.
8.Remove fixings, shock absorber to mounting
bracket.
9.Withdraw mounting bracket.
10.Lift off top seating washer, rubber bush and
cupwasher.Refit
11.Assemble shock absorber components.
12.Position shock absorber, complete with bracket
and secure with 4 fixings.
13.Secure shock absorber lower fixing.
14.Fit road wheel, remove chassis stands and jack. 
						

							FRONT SUSPENSION
5
REPAIR FRONT ROAD SPRING
Service repair no - 60.20.11.
Remove
1.Remove front shock absorber.
See Front
shock absorber
CAUTION: Avoid over stretching brake
hoses. If necessary loosen hose connector
locknuts to allow hoses to follow axle.
2.Lower axle sufficient to free road spring.
3.Withdraw road spring.
4.Withdraw shock absorber bracket securing ring.
Refit
5.Fit shock absorber bracket retaining ring. Retain
in position with a nut.
6.Position road spring and raise axle.
7.Remove nut retaining securing ring.
8.Fit front shock absorber.
See Front shock
absorber
BUMP STOP
Service repair no - 60.30.10.
Remove
1.Remove fixings.
2.Remove bump stop.
Refit
3.Position bolts in slots in chassis brackets.
4.Fit bump stop, secure with washers and nuts. 
						

							FRONT SUSPENSION
1
SPECIFICATIONS, TORQUE TORQUE VALUES
Nm lbf ft
Anti-roll bar front:
- Mounting brackets 30...................................................... 22
- Ball link self lock nut 70................................................... 50
- Castellated nut 40........................................................... 30
Drag link to axle 40............................................................... 30
Securing ring for mounting turret 14...................................... 10
Radius arm to chassis 175...................................................... 130
Panhard rod mounting arm to chassis 90............................. 65
Panhard rod to axle 90.......................................................... 65
Panhard rod to mounting arm 90.......................................... 65
Tie bar to Panhard rod 110..................................................... 80
Radius arm to axle 200........................................................... 150
Road wheel nuts 130.............................................................. 95 
						

							REAR SUSPENSION
1
DESCRIPTION AND OPERATION DESCRIPTION
The rear suspension locates the rear axle with two
round section steel lower link arms and a forged A
frame upper link assembly. This system allows
maximum axle articulation and wheel travel while
maintaining roll stiffness and directional stability.
The link arm is secured by a single retaining nut to the
chassis mounting, comprising a rubber bushed
bracket, which is retained by three fixings. A ferrule
rubber bush with a single retaining bolt is used to
secure the link arm to its axle mounting.
The upper link assembly is located on the rear
differential housing by a pivot ball-pin assembly. Two
brackets, bolted to the chassis crossmember,support both sides of the A frame of the link
assembly, secured by single retaining bolts.
Two rubber bearing bushes with retaining straps,
secure the rear of the anti-roll bar, if fitted, to the
chassis mountings, while bushed links support the
front of the anti-roll [sway] bar to the axle.
Conventional long travel coil springs and hydraulic
shock absorbers are used to control body movement.
The shock absorbers are secured to chassis mounting
brackets and fabricated lower mountings welded to to
the rear axle. Retaining plates are used to secure the
coil springs to the axle mounting while fabricated
brackets, welded to to the chassis, are used for the
upper spring location.
Rear axle suspension
1.A frame, upper link assembly
2.Lower link
3.Coil springs
4.Shock absorber 
						

							REAR SUSPENSION
1
REPAIR REAR ROAD SPRING
Service repair no - 64.20.01.
Remove
1.Loosen rear road wheel retaining nuts.
2.Support chassis on stands and remove wheels.
3.Support rear axle weight with jack.
4.Disconnect shock absorbers at one end.
5.Position coil spring compressor correctly on road
spring.
6.Compress spring evenly to facilitate removal.
7.Lower axle to free road spring from upper seat.
CAUTION: Avoid lowering axle further than
rear brake flexible hose and road speed
sensor leads will allow.
8.Remove spring retainer plate.
9.Withdraw road spring.
10.Collect off spring seat.
Refit
11.Position spring seat on axle location.
12.Fit road spring into chassis location and using a
turning motion, fit to spring seat.
13.Fit spring retainer plate.
14.Secure shock absorber. Tighten to
37 Nm, 27
lbf ft
15.Fit road wheels. Tighten to130 Nm, 95 lbf ft.
16.Remove chassis stands and jack.REAR SHOCK ABSORBER
Service repair no - 64.30.02.
Remove
1.Loosen road wheel retaining nuts.
2.Support chassis on stands. Remove road wheel
and support rear axle weight with jack.
3.Remove fixings and withdraw shock absorber
from axle bracket.
4.Remove upper fixings.
5.Withdraw shock absorber.
6.If required remove mounting bracket
7.If required remove mounting rubbers.
Refit
8.Position shock absorber and fit upper fixings.
9.Secure shock absorber with lower fixings to axle
bracket. Tighten to
37 Nm, 27 lbf ft.
10.Fit road wheels. Tighten to130 Nm, 95 lbf ft.
11.Remove chassis stands and jack. 
						

							64REAR SUSPENSION
2
REPAIR SUSPENSION LINK - UPPER
Service repair no - 64.35.44.
Remove
1.Support rear of chassis on stands, allow axle to
hang freely.
2.Remove fixings, upper link bracket to frame.
3.Remove fixings, upper links to pivot bracket.
4.Remove upper link complete with frame bracket.
5.Remove bolt.
6.Separate link from bracket.Renew bush
7.Press out rubber bushes.
8.Fit bush centrally in housing.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
Refit
NOTE: Do no fully tighten fixings until all
components are in position.
9.Secure link to frame bracket.
10.Fit upper link to pivot bracket.
11.Fit frame bracket to chassis mounting.
12.Fully tighten fixings to correct torque.
See
Specifications, torque, Torque values.