Land Rover Defender Workshop Rover Manual
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54FRONT AXLEANDFINAL DRIVE 4 OVERHAUL Swivel pinhousing 22. Remove boltssecuring oilseal retaining plate and joint washer. Release assembly fromswivel pin housing. NOTE: Removal ofoil seal andretaining plate isachieved whenswivel bearing housing isremoved. 23. Remove 2bolts, retaining lowerswivel pinto housing. 24. Remove brakediscshield bracket. 25. Tap lugtoremove lowerswivel pinand joint washer. 26. Remove twobolts retaining brakehosebracket and topswivel pin. 27. Remove bracket,topswivel pinand shims. 28. Remove swivelpinhousing whileretrieving lower andupper bearings. Swivel bearing housing 29. Remove lowerbearing trackfromswivel bearing housing. NOTE: Useupper bearing opening togain access tolower bearing track. 30. Remove 7bolts retaining swivelbearing housing to axle case. 31. Remove inneroilseal from back ofhousing. 32. Remove topbearing trackfromswivel bearing housing. NOTE: Uselower bearing opening togain access toupper bearing track. 33. Ifworn, pittedordamaged, renewhousing. 34. Fitupper andlower bearing tracksintoswivel bearing housing. CAUTION: Ensurebearing tracksarefitted square ordamage couldoccur. 35. With seallipstrailing, fitswivel housing inneroil seal intorear ofhousing. Greaseseallips. Fit swivel pinhousing 36. Coat swivel bearing housing toaxle casing bolts with Loctite 270orequivalent. 37. Coat bothsides ofjoint washer withasealing compound. Positionswivelbearing housing to axle mating face. Swivel assembly components 1.Swivel pinhousing 2. Top swivel pinand brake hosebracket 3. Upper andlower swivel pinbearings 4. Shim 5. Retaining plateandwasher 6. Oil seal 7. Joint washer 8. Swivel bearing housing 9. Joint washer 10. Lower swivelpin 11. Mudshield bracket 12. Swivel housing inneroilseal
FRONTAXLEANDFINAL DRIVE 5 OVERHAUL 38. Place retaining plate,jointwasher andoilseal over axleflange readyforassembly. 39. Fitswivel bearing housing toaxle flange with7 bolts. Tighten to 73Nm (54lbf/ft). 40. Grease andfitupper andlower swivel pintaper roller bearings. 41. Position swivelpinhousing overswivel bearing housing. 42. Coat jointwasher bothsides withsealing compound andposition onlower swivel pin. 43. Loosely fitbrake shield bracket pluslower swivel pin with lugoutboard toswivel pinhousing. 44. Loosely fittop swivel pinplus existing shimsand brake hosebracket toswivel pinhousing. 45. Apply Loctite 270orequivalent tolower swivel pin bolts. 78Nm (58lbf/ft),bend overlocktabs. 46. Tighten topswivel pinbolts to 78Nm (58lbf/ft). Check andadjust preload onbearings NOTE: Swivelhousing oilseal andaxle should notbefitted. 47. Attach aspring balance toball joint bore andpull balance todetermine effortrequired toturn swivel pinhousing. Resistance, onceinitial inertia hasbeen overcome, shouldbe1.16 to1.46 kg.Adjust by removing oradding shimstotop swivel pin. 48. When setting iscorrect remove topswivel bolts, apply Loctite 270orequivalent. Refitbolts and tighten to 78Nm (58lbf/ft),and bend overlock tabs. 49. Apply recommended greasebetween lipsof swivel oilseal. 50. Fitoilseal, jointwasher andretaining platewith 7 bolts andspring washers. Tightento 11Nm (8 lbf/ft). 51. Fittierod and drag linkand secure withnew cotter pins.Tighten fixingto 40Nm (30lbf/ft). 52. Fitbrake discshield. 53. Loosely fitlock stop boltand nut. 54. Apply arecommended greasebetween lipsof swivel housing oilseal. 55. Secure oilseal withretaining plateandsecuring bolts. Tighten to 11Nm (8lbf/ft). 56. Fittrack-rod anddrag linkand secure withnew cotter pins. 57. Loosely fitlock stop boltforlater adjustment. 58. Fitbrake discshield. Fit driveshaft andstub axle 59. Insert axleshaft, andwhen differential splines are engaged, pushassembly infully. CAUTION: Takecarenottodamage axle shaft oilseals. 60. Place anew jointwasher inposition onswivelpin housing tostub axlemating face.Coatthreads of stub axlebolts withLoctite 270. 61. Fitstub axlewithflatat12 Oclock position. CAUTION: Ensurethatconstant velocity joint bearing journalisbutted against thrust ringonstub axlebefore stubaxleis secured. 62. Place mudshield inposition andsecure stub axle toswivel pinhousing with6bolts and tighten evenlyto 65Nm (48lbf/ft). 63. Fitbrake jumphoses tobrake jumphose bracket. 64. Fitcomplete fronthubassembly See Repair, Front hubassembly . 65. Check swivelpinhousing oildrain plugisfitted. 66. Fillswivel assembly tocorrect level,withnew oil SeeSECTION 10,Maintenance, Under vehicle maintenance . NOTE:Onlater vehicles fillswivel pin housing with0.33Litres ofMolytex EP00 grease. 67. Setsteering lockstop bolts SeeSTEERING, Adjustment, Steeringlockstops .
FRONTAXLEANDFINAL DRIVE 1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE:Torque wrenches shouldberegularly checkedforaccuracy toensure thatallfixings are tightened tothe correct torque. Nm FRONT AXLE Hub driving member tohub 65* ....................................................................... Brake disctohub 73 ....................................................................................... Stub axletoswivel pinhousing 65* ................................................................. Brake caliper toswivel pinhousing 82 ............................................................ Upper swivelpintoswivel pinhousing 78* ..................................................... Lower swivelpintoswivel pinhousing 78* ..................................................... Oil seal retainer toswivel pinhousing 11 ........................................................ Swivel bearing housing toaxle case 73* ......................................................... Pinion housing toaxle case 41 ....................................................................... Crown wheeltodifferential housing 58 ........................................................... Differential bearingcaptopinion housing 90 .................................................. Differential driveflange todrive shaft 47 ......................................................... Mudshield tobracket lowerswivel pin 11 ........................................................ Bevel pinion nut 130 ........................................................................................ Draglink tohub arm 40 .................................................................................... Panhard rodtoaxle bracket 88 ....................................................................... Radius armtoaxle 190 .................................................................................... Radius armtochassis sidemember 190 ......................................................... NOTE: *These boltstobe coated withLoctite 270prior toassembly.
STEERING1 DESCRIPTION ANDOPERATION DESCRIPTION The steering systemincorporates acompression joint in the lower shaftandisdesigned tocollapse on impact. Themis-alignment ofthe upper steering column withthesteering boxand theinclusion oftwo universal joints,isalso designed toprevent the column movingtowardthedriver under frontal impact. The steering boxislocated behindthefirst chassis cross member andisconnected tothe road wheel swivel housing byadrag linkand track rod.A hydraulic damperabsorbs shocksinthe steering, caused byroad wheel deflections whenoperating on rough terrain. Power steering system The power steering systemcomprises ahydraulic pump which isbelt driven fromtheengine and supplied withfluid from areservoir thatalso actsasa cooler.The steering boxhouses aself neutralizing rotary valve which ispart ofthe worm/valve assyandan hydraulic piston/rack toassist themechanical operation. Therotary valvewhich isoperated by movement ofthe steering wheel,directs fluidpressure to the appropriate sideofthe hydraulic piston/rack to provide assistance. Powersteering system 1. Hydraulic pump 2. Fluid reservoir 3. Steering box 4. Upper column 5. Universal joints 6. Lower shaft 7. Compression joint 8. Drag link
57STEERING 2 DESCRIPTION ANDOPERATION Power steering boxcomponents 1. Housing complete withsector shaftbearings 2. Cover platecomplete withbearing 3. Sector shaft 4. Hydraulic piston/rack 5. Worm/valve andtorsion barassembly 6. Shims forcentralizing worm/valve 7. Ball race 8. Teflon sealsforvalve sleeve 9. Bearing adjuster, locknutandseal 10. Worm shaftpressure seal,circlip anddirt excluder 11. Teflon andrubber sealforpiston 12. End cover sealandsnap ring 13. Adjustment components forpiston/rack 14. Hydraulic pipe 15. Bleed screw 16. Sector shaftadjustment locknutwith seal 17. Cover platebolts 18. Cover plateseal 19. Seal, washer andbackup seal 20. Circlip anddust cover
STEERING3 DESCRIPTION ANDOPERATION Rotary valveoperation Rotary valveatneutral The rotary valveassembly comprises aworm (1), valve sleeve (2),input shaft(4)and torsion bar(5). The valve sleeve isretained insidetheworm byatrim screw (3),and incorporates valveportsinits inner bore. Theinput shaftisattached tothe steering wheel via asteering shaftandsteering columnand incorporates valveportsinits outer diameter toalign with those inthe sleeve. The torsion bar,which issecured tothe worm and input shaftwithpins (6)ateach end,holds thevalve ports inneutral alignment whenthereisno demand for assistance. No demand forassistance (Valveatneutral) When thereisno demand forassistance thetorsion bar holds theinput shaftandsleeve valveportsin neutral relationship toone another, allowingequal pump pressure (A)toboth sides ofthe piston/rack (9). Any excess fluidflowfrom thepump returns tothe reservoir via(B).
57STEERING 4 DESCRIPTION ANDOPERATION Rotary valvemisaligned Demand forassistance (Valvemisaligned) When thesteering wheelandinput shaftisturned, steering resistance transmitted tothe worm causes the torsion bartobe twisted andthevalve portstobe misaligned foraright orleft turn. Themisalignment of the valve portsdirects allfluid pressure Ato one side of the piston onlyandallows displaced fluidBon the other side. When demanding maximumassistance, any excessive fluidoutput fromthepump duetohigh pump speed, willcirculate throughtheregulator valve located inthe pump unit,causing thetemperature of the fluid andthepump torise rapidly.CAUTION: Toavoid excessive fluid temperatures whichcoulddamage theoil seals, thesteering mustnotbeheld onfull lock formore than30seconds inone minute. Only when thesteering wheel,andthedemand for assistance, isreleased, willthe torsion barreturn the valve toneutral, allowing thefluid tocirculate through the reservoir whereitis cooled. In the unlikely eventofmechanical failureofthe torsion bar,acoarse splined connection (7)between the input shaftandworm, ensures steeringcontrolis maintained sufficienttoallow thevehicle tobe recovered.
STEERING5 DESCRIPTION ANDOPERATION Pump andregulator valveoperation The pump which isbelt driven fromtheengine isan eccentric rollertypeandalso houses thepressure regulator andflow control valve.Thepressure is controlled byaspring loaded ballvalve (3)which is housed insidetheflow control valvepiston (4). No demand forassistance Highflowthrough box- Low pressure With nodemand forassistance therotary valveinthe steering boxacts asapressure reliefvalve, allowing fluid (A)toflow freely through thesteering boxand back tothe reservoir andpump inlet(B). Nodemand forassistance 1. Reservoir 2. Pump 3. Pressure controlballvalve andspring 4. Flow control valveandspring 5. Press fitplug (ballbearing) 6. Restrictor The ballplug (5)ispressed intothevalve (4) during manufacture anddetermines theopening pressure ofpressure reliefvalve (3). No flow, through box-High pressure When thesteering isturned, therotary valve effectively stopsallfluid flowthrough thesteering box, thus causing anincrease inpressure (A).This increase inpressure isfelt inthe flow control valve spring chamber where,atapre-determined pressure the relief valve (3)will open andallow thepressure to escape. Thefallinpressure inthe flow control spring chamber, allowstheflow control valvetomove tothe right, which inturn allows pumpoutput (A)toescape directly intothepump inlet(B). Assistance demanded As soon asthe steering wheelisreleased after making aturn, thesystem revertstothe condition seen inJ6292 andtheroad wheels arereturned tothe straight aheadposition bythe mechanical steering geometry. In the event ofany hydraulic failure,steering control, though heavy,willbemaintained throughthe mechanical components inthe steering box.
STEERING1 FAULT DIAGNOSIS INSUFFICIENT POWERASSISTANCE 1. Isfluid level correct? YES -go to 3. NO -Fill/bleed sytem 2. Isproblem aleak? YES -Diagnose See Power Steering Fluid Leaks . NO -continue 3. Isdrive belttension correct? YES -go to 5. NO -Is drive beltworn orcontaminated withoil? See ELECTRICAL, Repair,Auxiliary drive belt . 4. Isproblem resolved? YES -end NO -continue 5. Carry outpressure testatidle and 1000 rev/min. SeePower Steering System-Test. 6. Iscorrect pressure achieved? YES -steering boxdefective Not atany speed goto9. Not atidle goto7. 7. Isidle speed correct? Y ES -G oto8 . NO -Correct idlespeed - SeeENGINE TUNING DATA, Information, 300TdiEngine . 8. Isproblem resolved? YES -end NO -go to 9. 9. Bypass steering boxusing adaptor tap LRT-57-001 10. Iscorrect pressure obtained? YES -defective steeringbox NO -defective steeringpump CAUTION: Donot hold steering wheelon full lock formore than30seconds inany one minute toavoid overheating fluidand possibly damaging seals. NOTE:1.Excessive pressureinthe system isalmost always caused bya faulty reliefvalve inthe PAS pump. NOTE: 2.Insufficient pressureinthe system isusually caused bylow fluid level or PAS pump drivebeltslip, orone ofthe following: PASsystem leaks,faultyPASpump relief valve, faultinsteering boxvalve andworm assembly, leakatpiston insteering box,worn components inPAS pump orbox.
57STEERING 2 FAULT DIAGNOSIS POWER STEERING SYSTEM-TEST NOTE: Ifsteering lackspower assistance. Check pressure ofhydraulic pumpbefore fitting newcomponents. Usefault diagnosis charttoassist intracing faults. A.Steering box. B. Steering pump. C. Existing hose,steering boxtopump. D. Hose LRT-57-030 . E. Test adaptor LRT-57-001 . F. Pressure gaugeLRT-57-005 . G. Thread adaptor LRT-57-004 . H. Thread adaptor LRT-57-022 . Procedure 1. Ahydraulic pressuregaugeandtestadaptor is used totest power steering system.Thisgauge is able tomeasure 140kgf/cm 2 . The maximum power steering systempressure is77 kgf/cm 2 . 2. Under certain faultconditions ofthe hydraulic pump itis possible toobtain pressures upto105 kgf/cm 2 . It is important torealise thatpressure on gauge issame pressure beingexerted upon steering wheel.Whentesting, turnsteering wheel gradually whilereading pressure gauge. 3. Check andmaintain maximum fluidlevel of reservoir. 4. Examine powersteering unitsandconnections for leaks. Allleaks mustberectified before attempting totest thesystem. 5. Check steering pumpdrivebelttension and renew beltifnecessary, See ELECTRICAL, Repair, Auxiliary driveBelt . 6. Assemble testequipment andfitto vehicle, as shown inRR3959M. 7. Open tapofadaptor. 8. Bleed system, takecare nottooverload pressure gauge. 9. With system ingood condition, pressures should be: (A) Steering wheelheldonfull lock andengine running at1,000 rev/min, 70to77 kgf/cm 2 . (B) Steering wheelheldonfull lock andengine idling, 28kgf/cm 2 . Checks shouldbecarried outonboth fulllock positions. CAUTION: Donot maintain thispressure for more than30seconds inany one minute toavoid overheating fluidand possibly damaging seals. 10. Release steeringwheelandwith engine idling. Pressure shouldreadbelow 7kgf/cm 2 . 11. Ifpressures differtothose givenafault exists. 12. Todetermine iffault issteering boxorpump. Close adaptor tapforamaximum fiveseconds. 13. Ifgauge doesnotregister specified pressure, pump isfaulty. 14. Fitanew pump, bleedsystem andrepeat test.If low pressure orasubstantial imbalanceexists, fault isin steering boxvalve andworm assembly.