Land Rover Defender Workshop 1993 Rover Manual

							STEERING 
2. To remove the inner  bearing  cup and  shims 
jar  the  casing  on the  work  bench  or use  a 
suitable  extractor.  Alternatively,  if difficulty  is 
being  experienced,  warm the casing 
universally 
in an  oven  or in boiling  water. Do 
not, however,  attempt to apply  local heat since 
distortion 
of the  casing  may result.  Whilst the 
casing  is being  heated,  cool a suitable 
mandrel 
or round  bar to fit inside  the bearing 
cup.  Insert  the cooled  bar 
in the heated 
casing  to retract  the cup  to enable 
it to  be 
withdrawn  together with the shims  which must 
be retained  for reassembly. 
Ball  bearing  and cage  assemblies  Rack 
and piston 
NOTE: 
That  beneath  the visible  white Nylon  ring 
in the piston  groove,  there is a rubber  seal. 
1. Examine  the valve  and worm  inner and outer 
ball  races  and cups  and 
if either  is worn, 
pitted  or damaged  in any  way,  both the cups 
and  the ball  races  must be renewed. 
1. Examine  the outer  seal and if worn  or 
damaged  in any  way  it must  be renewed 
along  with the rubber  ring. 
2. Taking  care not to damage  the piston  outer 
diameter  remove the plastic  seal. 
3.  Likewise,  carefully remove the rubber  ring. 
4.  Examine  the rack  teeth 
for wear  and damage. 
5. Check  that the thrust  pad bearing  surface is 
free from wear  and scores. 
6. Check  the piston  outer diameters  for burrs 
and  damage  and repair  as necessary  using a 
fine  file and  emery  cloth. 
7.  Ensure  that the bottom 
of the groove  and the 
inside  walls are not damaged 
or burred. 
Repair  where necessary  in the  same  way as 
above 
14 REISSUED: FEB 1993  
						

							STEERING 
8. Fit 
a new  rubber  ring to the piston  groove. ASSEMBLE 
Warm  a new  white  Nylon  seal in hot  water 
and 
fit to  the  piston. NOTE:  When fitting  replacement  oil seals,  these 
9. Immediately,  whilst still warm,  carefully  insert must be lubricated,  before fitting,  with the 
the piston  squarely  into the casing  bore with recommended  steering box fluid. Also ensure 
the rack  outwards,  as illustrated,  and leave that  absolute  cleanliness  is observed  throughout 
until cool. the following  assembly  instructions. 
Fitting  input shaft oil seal 
1. Fit  a new  seal,  lipped  side first,  into the 
housing  noting that when  correctly  fitted the 
seal  backing  will seat  on the  first  shoulder  in 
the  bore. 
2. Insert  the extrusion  washer with the flat side 
downwards  facing the seal.  Secure  the 
assembly  with the circlip  and 
to ensure  that it 
is properly  located, tap  the  circlip into the 
groove  with a punch. 
Rack  thrust  pad and  adjuster 
1. Examine  the rack  pad adjuster  for general 
condition  particularly  the pad  bearing  surface. 
2. Renew the seal  and if necessary  the nylon 
thrust  pad behind  the grub  screw. 
3.  Check  the thrust  pad for wear  in particular  the 
flat  side  which  slides on the  reverse  side of 
the  piston  rack. 
REISSUED: FEB 1993 15  
						

							STEERING 
Fitting sector shaft seal 
1. With the lipped  side leading, fit the oil seal to 
the  casing  followed by a plain  fibre washer. 
2. Fit the  steel  backed  dust seal,  flat side 
downwards  towards the oil seal.  Secure  with 
the circlip ensuring  that it is properly  located 
in  the  groove. 
4 Fit a new  sealing  ring to the  worm  adjuster 
screw  and turn  the adjuster  clockwise  into 
the 
housing using special  tool LST 119 until the 
end  float  in the  input  shaft  is almost 
eliminated.  Fit the  lock
-nut  but do not  tighten 
until  the following  instructions  for setting  the 
input  shaft preload  are completed. 
Fitting  valve and worm assembly 
1. Fit the inner  bearing  cup and the original 
shims  to the  casing.  Use a suitable  bar 
approximately 
57 mm  diameter  to tap  the  cup 
squarely  into position. 
If the original  shims are 
not  available  fit shims  to the  value 
of 0,76  mm 
to  provide  a nominal  thickness. 
2. Fit the  inner  and outer  bearing  cages to the 
worm  using  petroleum  jelly only 
to hold  the 
cages 
in position. Do not  use  grease for this 
purpose  since 
it does not dissolve in the 
steering 
box lubricating  fluid and could  block 
the  fluid  passages  in the  valve  assembly. 
3.  Cover  the input  shaft splined  area with seal 
saver 
RO 1015 and  carefully  insert the shaft 
into  the casing  followed  by the  outer  bearing 
cup. 
16 REISSUED: FEB 1993  
						

							STEERING 
5. Fit the  torque  setting  tool RO 1016 to the 
input  shaft  and secure  with the grub  screw. 
Coil  a length  of cord  round  the tool  and attach 
a  spring  balance 
to the free  end.  Measure  and 
record  the rolling  resistance 
of the shaft  as 
the  spring  balance  is pulled. 
3. Fit  seal  saver  RO 606604  over the thread  and 
splines 
of the  sector  shaft and carefully  insert 
the  shaft  into the casing.  Align the centre  gear 
pitch  on the  rack  with the centre  gear tooth 
on 
the sector  shaft and at the  same  time rotate 
the  input  shaft about  a small  arc 
to allow the 
sector  roller 
to engage  the worm. 
6, 
To settle  the bearings,  turn the worm  adjuster 
again,  clockwise, 
to increase  the resistance 
over  that recorded  in the  previous  instruction 
by 
1.8 to 2,2 kg  (at  a radius  of 31,7  mm which 
is determined  by the  setting tool). 
7.  Now,  back-off the  worm  adjuster 
anti
-clockwise so that  the rolling  resistance 
recorded  in instruction 
5 is only  0,9 to 1,3  kg 
Tighten  the locknut  using special 
tool LST 
119. Check  the rolling  resistance  again in 
case tightening  the lock-nut has  altered  the 
setting. 
Fitting rack, piston  and sector shaft 
1. Screw a suitable bolt into the piston  crown to 
assist the fitting  and positioning  of the  piston 
as  was  recommended  for removing  the piston. 
2. insert  the piston,  rack end first,  into the casing 
so that  the piston  crown is approximately 63,5 
mm  from  the outer  end of the bore. 
REISSUED: FEB 1993 17  
						

							STEERING 
4. The illustration  below shows  the position  in Fitting sector shaft cover 
which the sector  shaft and roller  should  be in 
relation 
to the  casing  aperature  when the shaft 
is  being  inserted. 1. Fit and  lubricate  a new  sealing  ring to the 
inside 
of the  cover  and screw  the cover  fully 
on 
to the  sector  shaft adjuster  screw. If 
necessary,  use an Allen  key to hold the screw 
to prevent  it turning. 
2. Locate  the cover  on the  casing  noting that it 
can only  be fitted  one way,  that is, with  the 
bleed  nipple  towards  the worm  adjuster.  Tap 
the  cover  into place  and 
if necessary,  back off 
the  adjuster  screw a few  turns  to allow  the 
cover 
to seat  properly  on the  casing. Fit the 
3. Using  the torque  setting  tool RO 1016 for 
convenience,  rotate the input  shaft through  a 
small  arc, in both  directions,  to ensure  that the 
sector  roller is free 
to move  in the  worm. 
Tighten  the four  screws  evenly 
to the correct 
torque.  cover 
retaing screws 
but do not  tighten. 
Fitting rack adjuster 
1. Fit a new  sealing  ring to the rack  adjuster. 
2. Fit the  adjuster  pad with  the flat  side  towards 
the  rack  and screw 
in the adjuster  until solid 
contact  is made  with the rack.  Now back
-off 
the  adjuster  half a turn. 
3. Insert  the Nylon  locking  pad and fit the grub 
screw,  leaving 
it slack at this stage. 
18 REISSUED:  FEB 1993  
						

							STEERING 
Fitting cylinder  cover  Setting the sector  shaft and rack  adjuster 
pre
-loads 
1. Fit  and  lubricate  a new  seal  to the  cylinder 
cover  and press  the cover  squarely  into the 
1. Turn  the input  shaft to set  the  sector  shaft 
cylinder  just far enough  to clear  the retaining  roller 
at the  mid  point  of its  travel  between  the 
ring  groove.  left 
and  right  hand  locks. 
2. Secure  the cover  with the retaining  ring by 2. Using  a 6 mm Allen  key, turn the sector  shaft 
inserting  one end  of the  ring  into the cylinder  adjusting screw anti
-clockwise  to obtain 
groove 
so that it is  positioned 12 mm  beyond  backlash between the input  shaft and sector 
the  ring  extractor  hole 
in the side  of the  shaft. Now, turn the adjusting  screw clockwise 
cylinder.  until the backlash  is just  eliminated. 
3.  Using  the tool  RO 
1016 and spring  balance, 
measure  and record  the maximum  rolling 
resistance  at the  input  shaft. 
4. Fit a new  locknut  to the  adjuster  screw but do 
not  tighten.  Continue  to rotate  the input  shaft, 
with  the spring  balance,  whilst turning  the 
adjuster  screw until the figure  recorded 
in 
instruction 3 is increased  by 0,9  to 1,3 kg. 
Tighten  the locknut  and check  the  above 
figures  again. 
5. Turn the rack  adjuster  clockwise to impart 
Pressure upon the rack  and back-off half  a 
turn.  Again,  using special  tool RO 
1016 and 
the  spring  balance,  rotate the input  shaft 
whilst  turning  the rack  adjuster  until the figure 
recorded  in instruction  4 
is increased by a 
te  that  the final  rolling 
resistance  figure, 
recorded on the spring 3. Now,  compress  the ring  by hand,  whilst 
feeding  the ring  into the groove  by striking  it 
with  a hammer  until the ring  finally  springs 
into  position 
in the groove.  Ensure 
that the 
ring  is fully  seated  by tapping  it round 
with a 
punch. 
6. When  satisfied  that the pre-load  figures  are 
satisfactory,  lock the rack  adjuster  in position 
with  the grub  screw. 
REISSUED: FEB 1993 19 
further 0,9 to 1,3 kg. No 
balance, must not exceed 7,25 kg.  
						

							STEERING 
Torque peak check  NOTE: That 
the addition  or subtraction of a 0,07 
The  purpose 
of this check  is to determine  the point  mm shim  will move  the torque  peak area by 
at which  the rolling  resistance is the greatest  when  approximately  one quarter of a turn of the  input 
the  steering  is turned  from lock 
to lock. This  shaft. 
resistance,  which must be equally  distributed,  should 
be  when  the sector  shaft roller 
is positioned  along Shim washers  are available  from Land  Rover 
the  centre  portion 
of the worm  approximately  two Parts 
and Equipment in the following  sizes: 0,03 
revolutions  of the  input  shaft from either  the left 
or mm,  0,07 mm,  0,12 mm and  0,24  mm. 
right  hand  lock. 
3. Having  added or subtracted  shims as 
The  correct  position  of the  resistance  depends upon  necessary, reassemble  the steering  box and 
the  amount  of shimming  behind the input  shaft  inner  check that the torque  peak position 
IS now 
bearing  cup. Provided  that the original  shim pack  correct. 
has  been  refitted,  the torque  peak position  should be 
4. Using seal saver RO 606604, fit a new  outer 
correct  unless major components  have been  dust seal over  the sector  shaft. Fit the  drop 
renewed.  The procedure  for checking  and adjusting  arm 
to the sector  shaft and a new  lock 
the  torque  peak is contained  in the  following  washer. Fit and  tighten  the retaining  nut 
to the 
instructions.  correct 
torque and bend  the lock  tab over  a 
flat  of the  nut. 
1. Attach  the torque  setting  tool RO 1016 to the 
input  shaft  and turn  it fully  anti
-clockwise. 
Wind  cord round  the tool  and fasten  a spring 
balance 
to the  free  end as before.  Turn the 
input  shaft  by pulling  the spring  balance  and 
note  the position  where the highest  figure is 
obtained. 
If the  highest  figures are not 
recorded  along the middle  portion  of the  travel 
as  explained  above adjustment  is necessary. 
2. Adjustment  involves the dismantling  of the 
steering  box and  removal  of the  input  shaft 
inner  bearing  cup and  shims. 
If the torque 
peak  (highest  figure) occured  before the 
centre  position,  add shims 
to the pack. 
Remove  shims 
if the torque  peak occurs  after 
the  centre  Position. 
Fitting  steering box  to vehicle  and testing 
1. Fit the  steering  box to the  vehicle  and 
replenish  the system 
with the  correct  make 
and  grade  of fluid,  For this  information  refer 
to 
RECOMMENDED  LUBRICANTS AND 
FLUIDS’ 
and  bleeding  the power  steering 
system. 
2. 
To test  the effectiveness of the steering  box 
overhaul  and the system 
for leaks,  run the 
engine  and hold  the steering  hard on full  lock 
in  both  directions  whilst a second  person 
checks  for fluid  leaks. 
CAUTION: Do not  hold the steering  on full  lock 
for  more  than thirty  seconds 
in any one  minute 
to  avoid  overheating  the fluid  and possibly 
damaging  the seals. 
3. Finally  road test the vehicle. 
20 REISSUED:  FEB 1993  
						

							STEERING 
POWER STEERING SYSTEM - Adwest Test 
Lightweight  box 
If there is a lack of power  assistance  for the  steering 
Bleed the  pressure  of the  hydraulic  pump should be 
checked  first before  renewing  any components  of the 
system.  The fault  diagnosis  chart should  also be 
1. Fill the  steering  fluid reservoir to the mark  on 
the  side  of the  reservoir  with one of the  used to assist  in tracing  faults 
in the  power  steering. 
recommended  fluids. 
2. Start and run the engine  until it attains  normal 
operating  temperature. 
3. Check and correct the reservoir  fluid level. 
Procedure 
1. The hydraulic  pressure test gauge  is used  for 
testing  the  power  steering system. This gauge 
NOTE:  During the carrying  out of items 4, 5 and is calibrated to read  up to 140 kgf/cm²  and the 
6, ensure  that the steering  reservoir is kept full. normal  pressure  which may be expected in 
Do not  increase  the engine speed or move  the the power  steering  system is 77 kgflcm². 
steering  wheel. 2. Under  certain  fault conditions  of the  hydraulic 
pump  it 
is possible to obtain  pressures  up to 
4.  Run  the engine  at idle  speed,  slacken  the 
105 kgf/cm².  Therefore, it is important to 
realise that the pressure  upon the gauge is in 
direct  proportion to the pressure  being exerted 
upon  the steering  wheel. When testing,  apply 
pressure 
to the  steering  wheel very gradually 
while  carefully  observing  the pressure  gauge. 
3. Check, and if necessary  replenish, the fluid 
reservoir. 
4.  Examine  the power  steering  units and 
connections  for leaks. 
All leaks  must be 
rectified  before attempting 
to test the system. 
5. Check  the steering  pump drive belt for 
condition  and tension,  rectify as necessary. 
6. Assemble  the test  equipment  and fit to the 
vehicle  as illustrated. 
7. Open  the tap  in the  adaptor. 
8. Bleed  the system  but exercise  extreme care 
when  carrying  out this  operation 
so as not  to 
overload  the pressure  gauge. 
9. With the system in good  condition,  the 
pressures  should be as follows: 
a.  Steering 
wheel held  hard  on full  lock  and 
engine  running  at 1,000  rev/min,  the pressure 
should  be 
70 to 77 kgf/cm². 
b.  With  the engine  idling and the steering 
wheel  held hard  on full lock,  the pressure 
should  be 
28 kgf/cm²  minimum. 
These  checks  should be carried  out first  on one  lock, 
then  on the  other. 
CAUTION:  Under no circumstances  must the 
steering  wheel be held  on full  lock  for more  than 
30 seconds  in any  one  minute,  otherwise  there 
will be a tendency for the oil to  overheat  and 
possible  damage to the  seals  may result. 
bleed  screw.  When fluid seepage  past the 
bleed  screw  is observed,  retighten the screw. 
5. Ensure  that the fluid  level  is in  alignment  with 
the  mark  on the  reservoir  dipstick. 
6. Wipe off all fluid  released  during bleeding. 
7.  Check  all hose  joints,  pump and steering  box 
for  fluid  leaks  under  pressure  by holding  the 
steering  hard on 
full lock in both  directions. 
CAUTION:  Do not  maintain  this pressure for 
more  than 30 seconds  in any  one  minute,  to 
avoid  causing  the oil to overheat  and possible 
damage  to the  seals,  The steering  should 
be 
smooth lock-to-lock in both  directions,  that is, no 
heavy 
or light  spots  when changing  direction 
when  the vehicle  is stationary. 10. Release  the steering  wheel and allow  the 
engine 
to idle.  The pressure  should be below 
7 kgflcm². 
8. Carry out a short  road test. If necessary, 
repeat  the complete  foregoing  procedure. 
REISSUED: FEB 1993 21  
						

							STEERING 
11. If the pressures  recorded during the foregoing ADJUST  POWER STEERING BOX - Adwest 
test are outside  the specified  range, or Lightweight  box 
pressure imbalance IS recorded,  a fault  exists 
in  the  system. 
To determine if the fault  is in NOTE:  The condition of adjustment  which must 
the steering  box or the pump,  close the be checked is one of minimum  backlash without 
adaptor tap for a period  not exceeding  five overtightness  when the wheels  are in the 
seconds. straight-ahead position. 
12. If the gauge  fails to register  the specified 
pressures,  the pump 
is inefficient  and the 1. Jack  up the  front of the  vehicle  until the 
pump  relief valve  should  be examined  and  wheels 
are clear  of the  ground. 
renewed  as necessary. 
13. Repeat  the foregoing  test after  renewing  the WARNING:  Wheels  must be chocked in all 
relief  valve  and bleeding  the system. 
If the circumstances. 
pump  still fails to achieve  the specified 
pressures,  the pump  should  be overhauled  or 
2. Gently rock the steering  wheel about the 
a  new  unit fitted.  straight
-ahead 
position to obtain the feel of 
14. If pump  delivery  is satisfactory  and low  the backlash  present. This backlash  must not 
pressure  or marked  imbalance  exists, the fault  be more  than 
9,5 mm. 
must be in the  steering  box valve  and worm 3. Continue  the rocking  action whilst an assistant 
assembly.  slowly tightens  the steering  box adjuster 
screw  after slackening  the locknut  until the rim 
movement is reduced to 9,5 mm  maximum. 
4. Tighten  the locknut,  then turn the steering 
wheel from  lock to lock and check  that no 
excessive  tightness exists at any  point. 
5. Lower  the vehicle to ground  level and remove 
the  wheel  chocks. 
6. Road test the vehicle. 
A. Steering  box 
B.  Steering  pump 
C.  Existing  hose 
from steering  box 
22 REISSUED: FEB 1993  
						

							STEERING 
PIPE CONNECTIONS  TO STEERING BOX 
When  fitting a new  or overhauled  steering box 
observe  the following  procedure. 
1. Remove dust caps  from ports. 
2. Immediately  fit pipes  finger  tight. 
3. Tighten  the 16 mm union  nut to 20 Nm. 
4. Tighten  the 14 mm union  nut to 15 Nm. 
STEERING  BOX SECTOR  SHAFT SEAL - renew 
with  steering  box fitted  to vehicle 
Special  tools 
Drop arm  puller  MS 252A  / LRT
-57-012 
Seal  replacer  LST 125A  / LRT
-57-010 
1. Working from beneath  the vehicle  set the 
steering  in approximately  the straight  ahead 
6. Remove  the dust  seal, if fitted,  and clean  the 
position.  area around  the sector  shaft seal. 
2. Release  the ball  pin from  the drag  link, and 7. Remove  the circlip. 
one  end 
of Panard  rod. 
8. To remove the seal  pack,  drill two 3,0 mm 
3. Release  the lock  tab from  the drop  arm  holes diametrically  opposite into the metal  dirt 
retaining  nut and  remove 
the nut 
seal. Insert  a 4 mm  self tapping  screw in each 
hole  then,  with pliars  pull the seal  from  the 
box. 
9. Remove  the extrusion  washer and inner  seal. 
4. Before  removing  the drop  arm,  mark  its 
relationship  to the  sector  shaft to assist 
assembly. 
5.  Using  pulley MS 
252A or a suitable 
alternative,  withdraw the drop  arm. 
10. With  a suitable  probe, remove  the 
anti
-extrusion  washer and inner  seal. 
REISSUED: FEB 1993 23