Land Rover Defender Workshop Rover Manual

							STEERING1
ADJUSTMENT
POWER
STEERING BOX-ADJUST
Service repairno-57.35.01
WARNING: Adjustments ofsteering box
should notberequired whileinwarranty
period. Ifbox isstiff ortight andwithin
warranty, itmust bereturned tomanufacturer. No
attempt mustbemade tointroduce backlash.
1. Apply parkbrake brake, chockwheels andJack
up front ofvehicle untilwheels areclear of
ground.
2. Support chassisfrontonaxle stands.
3. Disconnect draglinkfrom steering droparm.
4. Check torquetoturn
See Fault diagnosis,
Stiff Steering Checklist
.
5. Centralise steeringbox
SeeCentralise
Steering Box
.
NOTE:Onlycheck fornobacklash when
steering boxisin central position.
NOTE:Ifsteering wheelisnot straight, it
should berepositioned
See Repair,
Steering Wheel
.
6.Adjustment isobtained byrocking thedrop arm
about centre whilstanassistant slowlytightens
the steering boxadjuster screw.
7. Tighten locknutwhenallbacklash hasbeen
removed. 8.
Repeat thecheck forbacklash. Ifbacklash exists
loosen locknut andrepeat adjustment
procedure.
9. Turn steering wheellocktolock andcheck no
tightness exists.
10. Ensure frontwheels arealigned andinstraight
ahead position.
11. Adjust draglink924 mmbetween balljoint
centres.
12. Connect draglinkand tighten to
40Nm (30
lbf/ft).
13. Lower vehicle toground levelandremove
chocks.
14. Road testvehicle
See Fault diagnosis, Road
Test Procedure
.
Drag linkadjust
1. RH drive vehicles -if steering wheelisto right,
drag linkistoo long. Ifsteering wheelisto left
drag linkistoo short.
LH drive vehicles -if steering wheelisto right,
drag linkistoo short. Ifsteering wheelisto left
drag linkistoo long.
2. Adjust draglinkuntil steering wheelpoints
straight aheadwhenvehicle istravelling ina
straight line.
CENTRALISE STEERINGBOX
Service repairno-57.35.05
LH drive vehicle
1. Disconnect draglinkfrom drop arm
SeeRepair,
Drag linkand drag linkends
.
2. Turn steering wheelonfull RH lock.
3. Turn steering wheelbackexactly twoturns.
4. Fitdrag link
SeeRepair, Draglinkand drag
link ends
.
RH drive vehicle
1. Repeat operation forLH drive vehicle butturn
steering wheelonfull LH lock.   
						

							57STEERING
2 ADJUSTMENT
STEERING
LOCKSTOPS
Service repairno-57.65.03
Check 1. Measure clearance betweentyrewall andradius
arm atfull lock. Thismust benot less than 20
mm.
Adjust 2. Loosen stopboltlocknut.
3. Turn stopboltasrequired.
4. Tighten locknut.
5. Check clearance betweentyrewall andradius
arm oneach lock.
NOTE: Alternatively lockstop adjustment
may becarried outusing following
procedure.
Check
1. Measure stopboltprotrusion A.Refer totable
for correct setting.
Adjust 2. Loosen stopboltlocknut.
3. Turn stopboltasrequired.
4. Tighten locknut.
5. Check wheelposition atfull lock. LOCK
STOPSETTINGS
Tyre &wheel size-alloys
Make SizeSetting
BF Goodrich MudTerrain 26559,7mm
Goodyear GT+4 23555,7mm
Michelin M+S4x4 23554,2mm
Tyre &wheel size-steel
Make SizeSetting
Goodyear 20552,2mm
Michelin 20552,2mm
Avon 7.5056mm
Michelin 7.5056mm
Goodyear 7.5056mm  
						

							STEERING3
ADJUSTMENT
FRONT
WHEEL ALIGNMENT
Service repairno-57.65.01
Checking Toe-outdimensions
NOTE:Recognised frontwheel alignment
and tracking equipment shouldbeused
for this operation. Onlytheuse ofbasic
equipment isdescribed below.NoAdjustment is
provided forcastor, camber orswivel pin
inclinations.
1. Set vehicle onlevel ground withroad wheels
positioned straightahead.
2. Push vehicle backandforwards tosettle linkage.
3. Set upthe equipment tomanufacturers
instructions andcheck alignment asadvised by
equipment supplier.
4. Position trammel probesoninner faceofwheel,
not therims, ifthe latter aredamaged.
5.Measure toe-outathorizontal centre-line of
wheels.
6. Check tightness ofclamp boltfixings. Tighten to
14Nm (10lbf/ft).
Adjust
7. Slacken clampsatboth ends oftrack rod.
8. Rotate trackrodtoincrease ordecrease its
effective lengthuntilcorrect toe-out isobtained
See GENERAL SPECIFICATION DATA,
Information, Steering
.
9.Push vehicle rearwards turningsteering wheel
from sidetoside tosettle balljoints. Withroad
wheels setinstraight aheadposition, push
vehicle forward ashort distance.
10. Recheck trackandadjust ifnecessary.
11. When alignment iscorrect, tapball joints in
direction ofarrows tomaximum oftravel, to
ensure fullunrestricted movementoftrack rod.
12. Tighten clampboltsto
14Nm (10lbf/ft).
POWER STEERING PUMPDRIVE BELT
Service repairno-57.20.01
Adjust
NOTE: Fordetails ofdrive beltadjust
procedure.
See ELECTRICAL, Repair,
Auxiliary DriveBelt    
						

							STEERING1
REPAIR
STEERING
COLUMN
Service repairno-57.40.01
Remove 1. Remove bonnet.
2. Set road wheels andsteering wheelinstraight
ahead position.
3.Mark relationship ofsteering columninnershaft
to top universal joint.
NOTE:collapsible shaftcanbe
disconnected fromsteering columnonly,if
required, byremoving boltsfromtop
universal jointandslackening topbolt oflower
universal joint.
4. Remove 2bolts fromtopuniversal jointand
lower boltofbottom universal joint.Slacken top
bolt oflower universal jointandwithdraw shaft. 5.
Prise centre capfrom steering wheel.
6. Remove steeringwheelretaining nutand
withdraw wheelfromcolumn spline.
7. Disconnect battery.
8. Remove 4screws securing instrument paneland
pull panel awayfromfacia toenable
speedometer cabletobe disconnected.
9. Disconnect multi-plugs, electricalleadsand
connections tovehicle alarmsystem, iffitted.
See ELECTRICAL, Repair,Vehicle
immobilisation andalarm system
.
10. Withdraw panelcomplete withinstruments.
11.Remove 5screws and2self-tapping screwsto
remove tophalf ofnacelle.
12. Ease bottom halfofnacelle fromswitch
gaiters/grommets andremove.     
						

							57STEERING
2 REPAIR
13.
Disconnect 3switch multi-plugs.
14. Slacken clampscrewontop ofswitch cluster
and withdraw switchassembly.
15.Note position ofharness leadsonback ofstarter
switch anddisconnect lucars.Iffitted, remove
alarm system passive coilfrom switch
See
ELECTRICAL, Repair,Vehicleimmobilisation
and alarm system
.
16. Using apunch orstud extractor remove2shear
bolts securing switchtocolumn.
17. Remove switchandcollect 2plain washers
between switchandclamp.
18. Remove brakepedalbox
SeeBRAKES,
Repair, Brakepedal
.
19. Remove boltsecuring tie-bartosteering column,
behind instrument panel.
20. Remove 2bolts securing columnlowersupport
to mounting bracket.
21. Remove boltssecuring twohalves oftop clamp
and bolts thatsecure tophalf ofclamp to
bulkhead.
22. Remove clampandrubber packing.
23. Remove 2bolts securing columnmainsupport
bracket tobulkhead.
24. Remove steeringcolumnandmain support
bracket fromvehicle.     
						

							STEERING3
REPAIR
NOTE:
Thesteering columnisanon
servicable component andcanonly be
serviced asacomplete assembly.
25. Fitmain support bracketandpadding tosteering
column andmanoeuvre columnintoposition in
vehicle.
26. Loosely securemainsupport bracketand
harness brackettobulkhead.
27. Loosely fitclamp andrubber packing stripto
column.
28. Loosely securelowerendofcolumn tolower
support bracket.
29. Loosely secureclampbracket tomain support
bracket.
30. Working insidevehicle cab,fittie-bar tocolumn
bracket andsecure withsingle boltto
22Nm (16
lbf/ft).
31. Finally, tightenmainsupport bracket, clamp
bracket, upperclamp, andlower support bracket
nuts andbolts. (M6bolts
9Nm (6 lbf/ft),M 8
bolts
22 Nm (16lbf/ft).
32. Fitbrake pedalboxSeeBRAKES, Repair,
Brake pedal
.
33. Fitsteering lock/switch inposition androtate
steering columninnershafttoline upslot with
switch plunger.
34. Secure locktocolumn withclamp andshear
bolts. Evenly tightenboltsbutdonot shear them.
35. Temporarily fitsteering wheelandoperate
switch andlock mechanism severaltimesto
ensure itfunctions correctly.
36. Fully tighten switchretaining boltsuntilheads
shear.
37. Connect electrical leadstorear ofswitch. Fit
alarm system passive coil,ifapplicable.
See
ELECTRICAL, Repair,Vehicleimmobilisation
and alarm system
38.Fitswitch assembly onsteering columnand
tighten clamping screw.
39. Connect switchassembly multi-plugs and
electrical leadstomain harness.
40. Offer upinstrument panel,connect speedometer
cable, multi-plugs andelectrical leadstomain
harness. Ifapplicable, fitvehicle alarmsystem
connections.
See ELECTRICAL, Repair,
Vehicle immobilisation andalarm system
.
41. Secure panelwith4screws.
42. Locate tophalf ofnacelle inposition andfitto
switch gaiters/grommets. 43.
Fitlower halfofnacelle andloosely tightenfixing
screws.
44. Ensure switchgaiters/grommets arecorrectly
located andfully tighten fixings.
45. Turn indicator cancelling ringsothat slots are
vertical andlugwith arrow points tothe left, in
direction ofindicator switch.
46. Fitsteering wheelwithfinisher attachment lugat
bottom, ensuring thatindicator cancelling forks
locate incancelling ringslots.
47. Secure wheelwithnutand new shake-proof
washer. Tightento
50Nm (37lbf/ft).
48. Fitsteering wheeldecal.
49. Ifnecessary, fitnew universal jointstosupport.
Note thatlong jointisfitted toshort length of
shaft andshort jointtolong end. Joints canonly
be fitted oneway toshaft.
50. With steering lockengaged androad wheels in
straight aheadposition, alignreassembly marks,
and fitcollapsible shaftassembly withlong legof
shaft tosteering box.Fitpinch boltsandtighten
to
25 Nm (18lbf/ft).  
						

							57STEERING
4 REPAIR
POWER
STEERING BOX
Service repairno-57.10.01
NOTE: Achassis undertray maybefitted
on some vehicle derivatives toconform to
legal requirements. Whenunder chassis
remove andrefit procedures arerequired, itmay
be necessary toremove theundertray
See
CHASSIS ANDBODY, Repair, Frontundertray
.
General precautions
Whenever anypart ofsystem, isremoved or
disconnected, utmostcleanliness mustbe
observed.
Disconnected portsandhoses mustbe
plugged toprevent ingressofdirt. Ifmetal
sediment isfound insystem, establish cause,
rectify andflush system.
Donot start engine untilreservoir isfull as
pump willbedamaged.
Metric pipefittings areused withOring pipe
ends onfittings tosteering box.
Follownormal Oring replacement procedure
whenever pipesaredisconnected.
Ensure compatible metriccomponents when
fitting replacement pipes.
CAUTION:Afterrefitting steering linkage
parts follow correct procedure toensure
that road wheels, steering boxand
steering wheelarecorrectly positioned relativeto
each other when instraight aheadcondition.
NOTE: Whendraglinkisdisconnected
from steering box,travel available at
steering wheeltoeach fulllock isnot
equal. Remove
1. Site vehicle onlevel surface.
2. Apply parkbrake, chockrearwheels, raise
vehicle andlocate axlestands. Alternatively,
raise vehicle onahoist.
3. Remove roadwheel.
4. Remove panhardrod
SeeFRONT
SUSPENSION, Repair,Panhard rod
.
5. Disconnect steeringdamperfromdrag link.
6. Disconnect draglinkfrom drop arm,seeJ6305
on opposite page,usingasuitable extractor.
7. Slacken, butdonot remove nutsecuring tiebar
to mounting arm. 8.
Remove 2bolts securing tiebar tosteering box
and move aside.
9. Remove fillercapfrom power steering fluid
reservoir.
10. Position suitablecontainer understeering box.
11. Disconnect feedandreturn pipesfromsteering
box and drain fluid.
12.Plug open pipes andsteering boxports to
prevent ingressofdirt. Refit fluidreservoir filler
cap.
13. Centralise steering
SeeCentralise steering
box
.
14. Remove pinchboltsecuring lowershaft
universal jointtopower steering box.
15. Remove 4bolts and2tab washers securing
steering boxtochassis sidemember.
16. Withdraw steeringbox.
17. Clean allmounting faces,unions etc.prior to
refitting.
Refit 18. Position steeringboxtochassis sidemember,
ensuring locatingpegisengaged. Fittab
washers andtighten boltsto
81Nm (60lbf/ft).
19. Fitpinch boltand nutsecuring universal jointto
power steering boxspline. Tighten to
25Nm (18
lbf/ft).
20. Secure tiebar tomounting armandsteering box.
Tighten fixingsto
81Nm (60lbf/ft),starting with
tie bar tomounting nut,then loosen fixingsby
one complete turn.
21. Check steering boxand adjust ifnecessary
See
Adjustment, Powersteering box-adjust
.
22. Refit draglinktodrop armandtighten nutto
40
Nm (30lbf/ft).
Fitnew splitpintoretaining nut.  
						

							STEERING5
REPAIR
REV: 09/97
23.Fitpanhard rodSeeFRONT SUSPENSION,
Repair, Panhard rod
.
24. Fitroad wheels. Lowervehicle toground and
tighten wheelnutstocorrect torque:
Alloy wheels -130 Nm(96lbf/ft)
Steel wheels -100 Nm(80lbf/ft)
Heavy dutywheels -170 Nm(125 lbf/ft)
25. Remove plugsandrefitfeed andreturn pipesto
steering box.Tighten 16mmthread to
20Nm (15
lbf/ft),
14mm thread to15Nm (11lbf/ft).
26. Remove fillercap. Fillreservoir tooil level mark
on dipstick, usingrecommended fluid
See
LUBRICANTS, FLUIDSANDCAPACITIES,
Information, Recommended lubricantsand
fluids
.
27. Bleed power steering system
SeePower
steering system-bleed
.
28. Recheck fluidlevel andreplace cap.
29. With engine running, teststeering systemfor
leaks byholding steering inboth fulllock
directions.
CAUTION: Donot maintain thispressure
for more than30seconds inany one
minute, toavoid oiloverheating and
possible sealdamage.
30. Test drive vehicle: usingbothfulllock directions,
to settle steering components. Ifpossible, drive
vehicle overuneven groundandinclude harsh
braking.
WARNING: Donot test drive vehicle on
public highway.
31. Drive vehicle inastraight lineonlevel ground
and stop.
32. Tighten tiebar tomounting nutto
110 Nm(81
lbf/ft).
33. Tighten tiebar tosteering boxfixings to81Nm
(60 lbf/ft).
34. Ensure steering wheeliscorrectly alignedwhen
wheels arepositioned straightahead.
35. Ifnecessary, repositionsteeringwheel
See
Steering wheel
.
36. Road testvehicle.   
						

							57STEERING
6 REPAIR
POWER
STEERING SYSTEM-BLEED
Service repairno-57.15.02
1. Check thatfluid level isat maximum level
See
MAINTENANCEMaintenance Underbonnet
maintenance
.
2. Run engine tonormal operating temperature.
3. Recheck reservoirfluidlevel, topupifnecessary
NOTE: During operations 4to 6,maintain
maximum fluidlevel inreservoir. Donot
increase enginespeedormove steering
wheel.
4. With engine atidle speed, slacken bleedscrew.
When fluidseeps pastbleed screw retighten
screw.
5. Check fluidlevel.
6. Clean awayfluidaround bleedscrew.
7. Check hoseconnections, pumpandsteering box
for fluid leaks byholding steering onfull lock in
both directions.
CAUTION: Donot maintain thispressure
for more than30seconds inany one
minute toavoid overheating fluidand
possibly damaging seals.
8. Carry outroad test. POWER
STEERING FLUIDRESERVOIR
Service repairno-57.15.08
Remove 1. Position draintinbeneath reservoir.
2. Slacken mounting bracketclampboltand raise
reservoir togain access tofeed andreturn hose
retaining clips.
3. Slacken clips,disconnect hosesfromreservoir,
allow fluidtodrain.
4. Remove reservoir.
CAUTION: Plugconnections toprevent
ingress ofdirt.
CAUTION: Discardfluiddrained from
system. Donot allow fluidtocontact
paintwork, ifspilled, remove fluidand
clean areawithwarm water.
Refit 5. Position reservoir, connectfeedandreturn
hoses andtighten clipsto
3Nm (2 lbf/ft).
6. Fitreservoir inclamp, tighten clampbolt.
7. Fill reservoir betweenuppermarkandendof
dipstick withpower steering fluid
See
MAINTENANCEMaintenance Underbonnet
maintenance
.
8. Bleed power steering system
SeePower
steering system-bleed
.   
						

							STEERING7
REPAIR
POWER
STEERING PUMP
Service repairno-57.20.14
Remove
NOTE: Achassis undertray maybefitted
on some vehicle derivatives toconform to
legal requirements. Whenunder chassis
remove andrefit procedures arerequired, itmay
be necessary toremove theundertray
See
CHASSIS ANDBODY, Repair, Frontundertray
.
1. Disconnect battery.
2. Remove viscousfanunit
See COOLING
SYSTEM, Repair,Viscous coupling andfan
.
3. Restrain steeringpumppulley, slacken butdo
not remove 3bolts securing pulley.
4. Remove drivebelt
SeeELECTRICAL, Repair,
Auxiliary drivebelt
.
5. Remove boltsandremove pulley.
6. Position suitablecontainer beneathsteering
pump.
7. Slacken retaining clipand disconnect return
hose fromsteering pump.
8. Disconnect highpressure pipefrom steering
pump.
9. Allow steering fluidtodrain intocontainer.
CAUTION: Plugallconnections toprevent
ingress ofdirt.
10. Remove 4bolts securing steeringpumpbracket
to engine auxiliary mounting bracket.
11. Remove pumpandbracket assembly.
12. Remove 3bolts anddetach mounting bracket
from pump.
Refit 13. Fitmounting brackettoreplacement steering
pump. Tighten boltsto
9Nm (7 lbf/ft).
14. Fitpump andbracket toauxiliary mounting
bracket. Tightenboltsto
35Nm (26lbf/ft).
15. Connect highpressure feedpipetosteering
pump andtighten to
20Nm (15lbf/ft).
16. Connect returnhosetosteering pump.Tighten
retaining clipto
3Nm (2 lbf/ft).
17. Position pulleytosteering pump,coatthreads of
bolts withLoctite 242;fitbut donot fully tighten
bolts.
18. Fitdrive belt
SeeELECTRICAL, Repair,
Auxiliary drivebelt
.
19. Restrain steeringpumppulley, tighten boltsto
10
Nm (7lbf/ft).
20. Fitviscous fanunitSee COOLING SYSTEM,
Repair, Viscous coupling andfan
.
21. Bleed power steering system
SeePower
steering system-bleed
.
POWER STEERING PUMPDRIVE BELT
Service repairno-57.20.02
NOTE: Fordetails ofdrive beltremove and
refit
See ELECTRICAL, Repair,Auxiliary
drive belt
.