Land Rover Defender Workshop 1993 Rover Manual

							SUSPENSION 
LEVELLING UNIT 
Functional check 
A Boge Hydromat  levelling unit is located  in the 
centre 
of the  rear  axle. 
When  the vehicle  is unladen  the levelling  unit has 
little  effect.  The unit is self
-energising  and hence  the 
vehicle  has 
to be driven  before  the unit  becomes 
effective,  the time  taken  for this  to happen  being 
dependant  upon the vehicle  load,  the speed  at which 
it  is  driven  and the roughness  of the  terrain  being 
crossed. 
If the  vehicle is overloaded  the unit  will fail to level  6. 
Load  weights to the value of 650  kg evenly 
fully  and more  frequent  bump stop contact will be  over the rear  load  area of the vehicle  and 
noticed.  leave it to  settle  undisturbed 
for minimum 
Should  the vehicle  be left  for a lengthy  period e.g.  period of thirty  minutes. 
overnight, 
in a  laden  condition,  it may  settle.  This is  7. With  the driving  seat occupied  or with  an 
due  to normal  internal  fluid movement  in the  unit  and  approximate equivalent weight of 
75 kg check 
is  not  detrimental 
to the  unit  performance.  the bump  stop clearance  and note  the 
Before  carrying  out he checks  below, verity that the  measurement. 
vehicle  is being  operated  within the specified  8. Drive  the vehicle  on a test  route 
maximum  loading capabilities. 
If the levelling  unit is  approximately 5 km in length  over undulating 
then  believed  to be  at fault,  the procedure  below  roads or graded  tracks. 
At the completion of 
should  be followed. 
the drive  bring  the vehicle to rest  by light 
Whilst  slight oil 
seepage 
is permissible,  the unit  brake application so as not to disturb  the 
should  be renewed 
if there  is an  excessive  oil leak.  vehicle loading. 
9.  Without  disturbing  the vehicle  load and 
with 
1. Remove  excessive  mud deposits  from  the driving  seat occupied,  check the bump 
underneath  the vehicle  and  any  heavy items  stop clearance  and note  the reading,  which 
from  inside  the vehicle  that are not part 
of the  must be in excess  of 45 mm (average). 
original  equipment. 
10. Subtract  the reading  obtained  under 
2. Measure the clearance  between the rear  axle  Instruction 7 from that obtained  under 
bump  pad and the bump  stop rubber  at the  Instruction 
9. If the change  in clearance  is in 
front  outer  corner  on both  sides  of the  vehicle,  excess 
of 10 mm the levelling  unit is 
dimension 
A. The  average  clearance  should  functioning correctly. 
be in excess of 67  mm. 11. If the  figures  obtained  in instructions 9 and 10 3. If the  bump  stop clearance  is less  than  the  do not  exceed 45 mm  and 10 mm respectively 
above  figure remove  the rear  springs  and  unload the vehicle  and renew  the levelling 
check  the free  length  against  the following 
unit. 
data in the chart. 
4. Renew  any spring  where the free length is 
more  than 
20 mm shorter  than the figures in 
the chart. 
5. Having  refitted or renewed  any springs  repeat 
the  clearance  check as described  above. 
If 
the average  bump clearance is still less  than 
67  mm  renew  the levelling  unit. 
LAND ROVER  COIL SPRING SPECIFICATION 
PART NO. DESCRIPTION  COLOUR 
CODE  LOCATION  SPECIFICATION 
FREE LENGTH 
NRC  6388  Drivers  Blue 
Stripe  Rear  Suspension 
420 mm 
NRC 
7000 Passengers  Green & White Rear  Suspension 400 mm 
Levelled 
Levelled 
Levelled  Stripes  Levelled  
						

							SUSPENSION 
REMOVE LEVELLING  UNIT  SPRINGS AND SHOCK  ABSORBERS 
WARNING: 
The  levelling  unit contains Remove  rear springs 
pressurised  gas and  must  not be dismantled  nor 1. Slacken the rear  road  wheel  nuts and raise 
the  casing  screws  removed.  Repair is by  the rear  of the  vehicle  and lower  the chassis 
replacement 
of complete unit only.  on 
the  axle  stands  or similar  supports  and 
remove  the road  wheels. 
1. Raise  and support  the vehicle  under the 2. Support  the weight  of the  axle  with a jack. 
3. Disconnect  the shock  absorbers  at the  lower 
chassis  and use a jack  to support  the weight 
of  the  axle.  end. 
2. Disconnect the upper  links at the  pivot  4. Remove  the spring  retainer  plate. 
bracket. 
5. Lower  the axle  sufficiently to withdraw  the 
3. Ease up the  levelling  unit lower  gaiter  and  spring, but take  care  not to stretch  the flexible 
unscrew  the lower  ball joint  at the  push  rod  brake hose by lowering  the axle  too far. 
using  thin jawed  spanners. 
6. Remove  the spring  pan. 
4. Release  the webbing  strap from the chassis. 
5. Remove  the four  nuts  securing  the top bracket Fit rear  springs 
to the chassis  and withdraw  the levelling  unit 
complete  with bracket. 7. Fit the  spring  pan and  retainer  plate. 
8. Fit the  spring  into the chassis  top location  and 
using  a turning  motion 
fit the 
spring to the 
Renew  levelling  unit ball joints axle pan. 
9. Secure  the shock  absorbers  with the rubbers 
The  ball joints  for the  levelling  unit may  be  correctly located. 
dismantled  for cleaning  and examination.  10. 
Remove  the axle  support, 
fit the road  wheels 
6. Unscrew  the lower  ball joint  from  the pivot  and lower  the vehicle to ground. 
bracket. 
11. Finally  tighten  the road  wheel  nuts. 
7. Unscrew  the ball  joint  from  the  top  bracket. 
8. Reassemble  the ball  joints,  packing  with Remove  shock absorbers 
Dextagrease G.P. or equivalent  or if 12. Slacken  the road  wheel  nuts, raise the rear of 
necessary  renew the joints if worn.  the 
vehicle  and support  it under  the axle  and 
9. Check  the condition of the gaiters  and renew  remove 
the road  wheels. 
if necessary.  13. Remove  the shock  absorber  upper and lower 
retaining  nuts and rubbers. 
Fit levelling  unit 14. Remove  the shock  absorber  from the top 
locating  shaft and withdraw  it from  the vehicle. 
10. Ensure  the ball  pin threads  are clean  and 
smear  Loctite  grade CVX on the  ball  pin 
Test  shock  absorbers 
threads. 15. Hold the shock  absorber  vertically in a vice, 
11. Fit  the  upper  ball joint to the levelling  unit and 
secure  the gaiter. 
16. The  shock  absorber  employs differential 
12. Fit the top  bracket  complete  with levelling  unit  damping having greater  resistance  on the 
to  the  chassis  and secure  with the four  nuts  extension stroke. Check operation  by 
and  tighten 
to 47 Nm.  extending 
and compressing  the shock 
13.  Fit the  levelling  unit 
to the lower ball joint  and  absorber. 
secure  the gaiter.  Resistance 
should be uniform  throughout  the 
14. Attach the webbing  strap to the  chassis  cross  length of each  stroke. If resistance  is erratic 
member.  or weak,  renew  the shock  absorber.  When 
15. Fit the  upper  links to the pivot  bracket  and  checking resistance  a new  shock  absorber 
retain  with the 
two bolts and nuts  but do not  may be used  for comparison. To ensure  that 
tighten  at this  stage.  the new  shock  absorber 
IS primed, fully 
16. Remove  the jack  in support  of the  axle  and  extend and compress  the unit  several  times 
the  support  from under  the chassis.  before testing  begins. 
17. Allow the suspension  to settle  and then 
tighten  the 
two bolts and nuts  retaining  the 
upper  links 
to the pivot  bracket to the correct 17. Fit the  shock  absorbers  using new rubbers 
torque.  and fit the  lower  rubbers  and caps 
in the 
18. Fit the  road  wheels,  lower the vehicle  and 
being 
careful  not 
to damage  the threads. 
Fit shock  absorbers 
order illustrated. 
finally  tighten  the road  wheel  nuts.  
						

							SUSPENSION 
PAN HARD ROD                                                                                RADIUS ARM 
Remove  Remove 
1. Remove fixings at mounting  arm. 1. Loosen road wheel  retaining  nuts. 
2. Remove fixings at axle  bracket. 2. Raise  front of vehicle.  Support  chassis on 
3. Remove Panhard rod.  stands 
and remove  wheel. 
4. Press out flexible  bushes.  Ensure the steel 3. Support  front axle weight  with  jack. 
tubing  locates  on the  outer  edge of the  bush 
and  not on the  rubber  inner. 
4. Remove  radius arm to chassis  side member 
fixings. 
5. Disconnect  track rod at ball  joint. 
6. Remove  fixings, radius arm to axle. 
7. Lower  radius arm front  end to clear  axle and 
remove  from vehicle. 
Refit 
5. Fit replacement  bushes. 
CAUTION: Apply pressure  to outer  edge of bush, 
and  not rubber  inner. 
6. Reverse 1 to 4. Tighten  fixings to 88Nm.  
						

							SUSPENSION 
8. Press out flexible  bushes. 
Refit 
9. Press  in replacement  bushes.  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 
CAUTION: When  pressing  in new  bushes  press 
on  outer  edge of bush  and not 
rubber inner. 
10. Reverse 1 to 7. Tighten  fixings to following 
torques:  cupwasher. 
Radius  arm to chassis  176Nm. 
Radius  arm to axle  197Nm. 
Refit 
FRONT SHOCK  ABSORBER 11. Reverse  instructions  1 to 10. 
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  e cupwasher,  rubber bush and 
seating  washer. 
5. Remove  four shock  absorber  bracket fixings. 
6. Withdraw  shock absorber  and bracket 
complete.  
						

							SUSPENSION 
FRONT ROAD SPRING BUMP STOP 
Remove  Remove 
1. Remove front shock  absorber. 1. Remove  fixings. 
CAUTION: Avoid over stretching  brake hoses.  If 
necessary  loosen 
hose connector locknuts to 
allow hoses to follow axle. 
2. Remove  bump stop. 
2. Lower  axle sufficient  to free  road  spring. 
3.  Withdraw  road spring. 
4. Withdraw  shock absorber  bracket securing 
ring. 
Refit 
3.  Position  bolts in slots  in chassis  brackets. 
4. Fit bump  stop, secure  with washers  and nuts. 
Refit 
5. Fit  shock  absorber  bracket retaining  ring. 
6. Reverse 2 and 3. 
7. Remove nut retaining  securing ring. 
8. 
Fit front  shock  absorber. 
Retain 
in position  with a nut.  
						

							SUSPENSION 
ANTI-ROLL BAR ASSEMBLY 
KEY 
1. Anti-roll bar 5. Nut  and  washer 
2. Rubber  bush 6. Castellated  nut and  cotter  pin 
3.  Strap 
7. Ball  joint  link arm 
4. Nut,  bolt,  washer 
ANTI-ROLL  BAR FRONT Refit 
Remove 4. Position  bushes on anti-roll  bar.  Ensure  split 
points  towards  axle. 
1. Mark for reassembly  position of rubber bushes 5. Fit anti-roll  bar with  two straps. To ensure 
on  anti
-roll  bar. 
correct fit angled  sides of bar  should  point 
2. Remove  four nuts, bolts and washers  securing  down 
as shown.  Loosely  fit the  bolts,  washers 
two  bush  straps.  and nyloc  nuts. 
3.  Remove  nuts, bolts,  washers  and rubber 
6. Fit bolt,  washers  and rubber  bushes.  Using 
bushes  from ball joint  links  and remove  new nuts fit anti
-roll  bar  to ball  joint  links. 
anti
-roll  bar.  Tighten to 68Nm. 
7. Tighten nuts securing  straps to 30Nm  
						

							SUSPENSION 
ANTI-ROLL BAR BALL JOINT LINKS 
Remove 
1. Remove  two nuts,  bolts,  washers  and rubber 
bushes  from ball 
joint links. 
2. Remove  cotter pin and  loosen  castellated  nut 
a 
few turns. 
3. Release  ball joint  using special tool 18G 
1063A  as shown. 
4. Remove  castellated  nut and  ball joint  link. 
Refit 
5. Fit  ball  joint  link and  castellated  nut. Ensure 
ball  joint  link arm  points 
up. Tighten  to 40Nm 
and fit new  cotter  pin. 
6. Align anti-roll bar  to ball  joint  links. 
7. Fit bolts,  washers  and rubber  bushes  using 
new  self locking  nuts secure  anti
-roll bar  to 
ball 
joint links.  Tighten  to 68Nm.  
						

							BRAKING SYSTEM 
BRAKES 
DESCRIPTION 
The  mechanical  components of the Defender 90 
braking  system consists  of four  piston  caliper  disc 
brakes  at the  front  and twin  piston  caliper  disc 
brakes  at the  rear.  The Defender 
110 system 
consists  of single  cylinder  drum brakes  at the  rear 
and  four  piston  caliper  disc brakes  at the  front.  The 
cable  controlled  handbrake,  common 
to both 
vehicles,  is a mechanically  operated single drum 
type  brake  mounted  on the  output  shaft of the 
transfer  box and  is completely  independent  of the 
main  braking  system.  Adjustment 
of all drum  brakes 
is  by  a snail  cam turned  by a square  peg on the 
back
-plates.  Caliper  disc brakes  are self  adjusting. 
The  basic  hydraulic  system involves 
two separate 
and  independent  primary and secondary  circuits 
which  permit  a degree  of braking  should a fault 
occur 
in one of the  circuits,  The primary  circuit A Right hand front brake 
operates  the rear  brakes  and the secondary  circuit  B Left  hand  front brake 
controls  the front  brakes.  The tandem  master 
C Right hand rear brake 
cylinder,  which is assisted  by a 
type 80 direct  acting D Left hand  rear brake 
servo,  is fed  by a divided  fluid reservoir.  The rear  E Jump  hose 
section  contains  fluid for the  primary  circuit and the  F 
LS.C. 
80 servo  and master  cylinder  assembly 
front  portion  supplies  fluid for the  secondary  circuit. 
G G valve 
A brake fluid loss switch  is fitted  to the  master 
cylinder  filler cap.  The switch  is wired 
to a warning 
lamp  bulb on the  drivers  control  panel and the bulb 
will  illuminate  momentarily  when the starter  motor is 
actuated,  indicating  that the brake  warning  circuit is 
functioning  correctly. 
A hydraulic failure in the 
primary 
or secondary  circuits will result in fluid loss 
and cause  the warning  bulb to illuminate, in such an 
event,  the driver  must 
stop the vehicle  immediately 
and  investigate  the cause. 
The  G valve  allows  fluid 
to the rear brakes  until a 
predetermined  pressure 
is reached when the valve 
closes.  The valve,  from 
this point on, will only  permit 
a  proportion  of any  increase 
in fluid  pressure to 
reach  the rear  brakes  to prevent  premature  locking 
of the rear wheels. Should a failure occur in the front 
brake  secondary  circuit the design 
of the valve will 
ensure  that the fluid to the  rear  brakes will by-pass 
the  valve  and allow  full circuit  pressure  to the  rear 
wheel cylinder.