Land Rover Defender Workshop Rover Manual
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STEERING3 OVERHAUL INSPECTING Piston 22. Discard allrubber sealsandobtain replacements. NOTE: Arubber sealisfitted behind plastic ringonrack piston. Discard seal and plastic ring. Steering boxcasing 23. Examine pistonboreforscoring andwear. 24. Examine feedtube. 25. Fitanew feed tubeifdamaged. Tightenunionto 22Nm (16lbf/ft). Sector shaftassembly 26. Check thereisno side playonroller. 27. Ifside playonroller exists fitanew sector shaft. 28. Check condition ofadjuster screwthreads. Check adjuster endfloat. Fitnew adjuster ifend float exceeds 0.15mm. 29. Examine bearingareasonshaft forexcessive wear. 30. Examine gearteeth foruneven orexcessive wear. Sector shaftcover assembly 31. Inspect coverandbearing. Ifworn ordamaged, fit anew steering box. Sector shaftadjuster locknut 32. The locknut isalso afluid seal. Fitnew nutat overhaul.
57STEERING 4 OVERHAUL Valve andworm assembly 33. Examine bearingareasforwear. Theareas must be smooth andnotindented. 34. Examine wormtrackwhich mustbesmooth and not indented. 35. Check forwear ontorsion barassembly pin.No free movement shouldexistbetween inputshaft and torsion barorbetween torsionbarand worm. NOTE: Anysign ofwear makes itessential to fitnew valve andworm assembly. 36.Examine valveringsforcuts, scratches and grooves. Thevalve ringsshould befree torotate in grooves. 37. Ifrequired, replaceallthree rings, usingring expander LRT-57-019 .The expander willnot pass overrings already fitted.Remove ringsto allow access without damaging sealgrooves. 38. Warm ringsandexpander tooltoaid assembly. Fit rings toexpander, slideexpander overvalve and worm assembly. Inturn fitrings totheir grooves. Removeexpander, slidevalve and worm assembly intoring compressor LRT-57-020 andallow tocool. Ball bearing andcage assemblies 39. Examine ballraces andcups forwear and general condition. 40. Ifball cage hasworn against bearing cup,fit replacements. 41. Bearing ballsmust beretained bycage. 42. Bearing andcage repair iscarried outby complete replacement ofassembly.
STEERING5 OVERHAUL Rack thrust padandadjuster 43. Examine thrustpadforscores. 44. Examine adjusterforwear inpad seat. 45. Fitnew sealing ringtorack adjuster. Rack andpiston 46. Examine forexcessive wearonrack teeth. 47. Ensure thrustpadbearing surfaceisfree from scores andwear. 48. Ensure pistonouterdiameters arefree from burrs anddamage. 49. Examine sealandringgroove forscores and damage. 50. Fitnew ringtopiston. Warmnylonsealandfitto piston. 51. Slide piston assembly intocylinder withrack tube outwards. Reassemble NOTE: Whenfitting replacement oilseals lubricate withrecommended fluidand ensure absolute cleanliness. Sector shaftoilseal 52. Fitoilseal, lipside first. 53. Fitextrusion washer. 54. Fitdust seal, lipped sidelast. 55. Fitcirclip. Fitting valveandworm assembly 56. Refit original shimsandinner bearing cup.Use Petroleum Jellytoaid assembly. NOTE: Iforiginal shimsarenot used, fit shims of0.76 mmthickness. 57. Fitinner cageandbearings assembly. 58. Fitvalve andworm assembly. 59. Fitouter cageandbearings assembly. 60. Fitouter bearing cup.
57STEERING 6 OVERHAUL 61. Fitnew worm adjuster sealingring. 62.Loosely screwadjuster intocasing. 63. Fitlocknut, donot tighten. 64. Turn inworm adjuster untilendfloat isalmost eliminated. Ensurebearing cagesareseated correctly. 65. Measure maximum rollingtorque ofvalve and worm assembly, usingatorque wrench and spline socket LRT-57-025 . 66. Turn inworm adjuster whilerotating shaftto increase figuremeasured to0.56 Nm. 67. Back offworm adjuster 1/4turn. Turn inworm adjuster toincrease readingby0.21 -0.34 Nm with locknut tight, 100Nm(74lbf/ft).Use worm adjusting wrenchLRT-57-006 andlocknut wrench LRT-57-028 . Fittingrackandpiston 68. Screw slaveboltintopiston toaid assembly. 69. Fitpiston andrack sopiston is70 mm (2.75 in) from outer endofbore. Fitting sectorshaft 70. Fitsector shaftusing sealsaver LRT-57-021 . Align rollerwithcutout incasing asshown. Push in sector shaftwhile rotating inputshafttoallow sector rollertoengage worm. Fittingrackadjuster 71. Fitrack adjuster andthrust padtoengage rack. Back offhalf turn onadjuster. 72. Loosely fitnew nylon padandadjuster setscrew assembly.
STEERING7 OVERHAUL Fitting sectorshaftcover 73. Fitnew sealing ringtocover. 74. Align cover withcasing. 75. Screw coverassembly fullyontosector shaft adjuster screw. 76. Ifnecessary backoffsector shaftadjuster screw. Tap cover inplace toallow cover tojoint fully with casing. NOTE: Before tightening fixings,rotate input shafttoensure sectorshaftroller is free tomove invalve worm. Ifinitial resistance isleft, turn adjuster screw approximately twoturns inaclockwise direction. 77. Fitcover bolts.Tighten to 75Nm (55lbf/ft). Fitting cylinder cover 78. Fitnew square section sealtocover. 79. Remove slaveboltfitted atinstruction 68.Press cover intocylinder justtoclear retainer ring groove. 80. Fitretaining ringtogroove withoneendofring positioned 12mm from extractor hole. Adjusting sectorshaft NOTE: Refitdrop armandtighten nut sufficiently toensure thatnobacklash exists between droparmandsector shaft. 81.Toset worm oncentre, rotateinputshafttofull inner-lock (fullright lockforaleft hand drive vehicle, fullleft lock foraright hand drive vehicle). Rotateinputshaftbacktowards centre two fullturns. 82. The boxisnow oncentre andcanbeadjusted. 83. Hold input shaftandrock drop armtoestablish backlash ispresent. Continue rockingandslowly turn sector shaftadjusting screwclockwise. Continue rotatingadjuster screwuntilbacklash has almost beeneliminated.
57STEERING 8 OVERHAUL 84. Refit locknut andtighten. NOTE: Itis important steeringboxis centralised beforeanyadjustments are made. 85. Check maximum rollingtorque oneandaquarter turns either sideofcentre position, usinga torque wrench andspline socket LRT-57-025 . Rotate adjuster screwtoobtain across centre torque of0.34 Nmplus torque figureatone and a quarter turns.Tighten adjuster locknutto 60 Nm (44lbf/ft). Adjusting rackadjuster. 86. Turn inrack adjuster toincrease figure measured ininstruction 85.by0.23 -0.34 Nm. The final figure maybeless, butmust not exceed 1.35Nm. 87. Lock rackadjuster inposition withgrub screw. Tighten to 5Nm (4 lbf/ft). Torque peakcheck With input shaftrotated fromlocktolock, rolling torque figures shouldbegreatest acrosscentre position andequally disposed aboutcentre position. The condition dependsonvalue ofshimming fitted between valveandworm assembly innerbearing cup and casing. Theoriginal shimwasher valuewillgive correct torquepeakposition unlessmajorcomponents have been replaced. Procedure 88. With input coupling shafttoward theoperator, turn shaft fullycounter-clockwise. 89. Check torquefigures obtained fromlocktolock using torque wrench andspline socket LRT-57-025 . 90. Check alsoforequal engagement eithersideof centre.Adjustments 91. Note where greatest figuresarerecorded relative tosteering position.If greatestfiguresare not recorded acrosscentreoftravel (steering straight-ahead), adjustasfollows: If torque peakoccurs before centreposition, addto shim washer value;iftorque peakoccurs aftercentre position, subtract fromshim washer value, referto fitting valveandworm assembly . Shim washers areavailable asfollows: 0.03mm, 0.07mm,0.12mmand0.24mm. NOTE: Adjustment of0.07mm toshim value willmove torque peakareaby1/4 turn onthe shaft. CAUTION: Whenreshimming valveand worm, extreme cautionmustbeexercised to prevent sealdamage during reassembly.
STEERING9 OVERHAUL Input shaftoilseal 92. Fitseal, lipside first, intohousing. Useseal saver LRT-57-016 andseal installer LRT-57-026 .Note thatseal isfitted toadepth of 4.75 -5.00 mmfrom faceofbox. 93. Secure sealwithcirclip. 94. Smear innerlipofdirt excluder withPTFE grease. Fitdirt excluder usingLRT-57-027 . When fittedcorrectly outershoulder ofexcluder is 4.00 -4.50 mmfrom faceofbox, dimension X. 95.Remove droparm.Smear innerlipofdirt excluder withPTFE grease andrefit, ensuring outer lipisflush withcasing. 96. With input shaftoncentre, alignassembly marks on drop armandsteering box.Fitdrop armto steering boxusing anew tabwasher. Tightento 176Nm(130 lbf/ft),bend overtab. 97. Fitsteering box SeeRepair, PowerSteering Box .
STEERING1 SPECIFICATIONS, TORQUE TORQUE VALUES NOTE:Torque wrenches shouldberegularly checkedforaccuracy toensure thatallfixings are tightened tothe correct torque. Nm Ball joint nuts 40 .............................................................................................. Clamp boltnuts 9 ........................................................................................... Steering columnbracket nuts 22 .................................................................... Steering wheelnut 50 ..................................................................................... Tie bar tomounting nut 110 ............................................................................. Universal jointpinch bolt 25 ............................................................................ PAS box Adjuster locknut 60 ................................................................................. Drop armnut 176 .................................................................................... Sector shaftcover tosteering box 75 ..................................................... Steering boxtochassis 81 ..................................................................... Steering boxfluid pipes 14mm thread 15 ............................................... Steering boxfluid pipes 16mm thread 20 ............................................... Tie bar 81 ............................................................................................... PAS pump High pressure fluidpipe 20 ..................................................................... Power steering pumpmounting 35 ......................................................... Pulley bolts,power steering pump 10 .................................................... Hose clamp 3 ........................................................................................ Front mounting platebolts 9 .................................................................. PAS reservoir Hose clamp 3 ........................................................................................ * Torque valuesbelowareforallscrews andbolts usedexcept forthose thatarespecified otherwise. METRIC Nm M5 6 ...................................................................................................... M6 9 ...................................................................................................... M8 25 ..................................................................................................... M10 45 ................................................................................................... M12 90 ................................................................................................... M14 105 .................................................................................................. M16 180 .................................................................................................. UNC /UNF 1/4 9 ...................................................................................................... 5/16 24 ................................................................................................... 3/8 39 ..................................................................................................... 7/16 78 ................................................................................................... 1/2 90 ..................................................................................................... 5/8 136 ....................................................................................................
FRONTSUSPENSION 1 DESCRIPTION ANDOPERATION DESCRIPTION The front suspension designallowsmaximum wheel travel andaxle articulation providinggoodground clearance withoutlossoftraction ordirectional stability.Long radius armsarefitted tothe front axleand provide maximum axlearticulation whichisvital foroff road performance. Theradius armsaresecured to fabricated mountingbracketsweldedtothe front axle. Flexible rubberbushes areused onastem endjoint to secure therear ofthe radius armstomountings on the chassis crossmember. A panhard rod,which ensures thatthefront axle remains centrally located,isfitted transversely and also uses ferrule rubber bushmountings atboth axle and chassis locations. Two rubber bearing bushes, withretaining straps, secure therear ofthe anti-roll bartothe chassis mountings, whilebushed linkssupport thefront ofthe bar tothe front axle. Conventional longtravel coilsprings andhydraulic shock absorbers areused tocontrol bodymovement in all conditions. Theshock absorbers aresecured to fabricated towerswhicharebolted tothe chassis. The upper andlower fixings useasingle location studwith flexible rubberbushes, supportwashers andsecuring nuts. Retaining platesareused tosecure thecoil springs tothe fabricated towersandaxle mountings. Rubber bumpstopsarefitted underneath thechassis, adjacent tothe front road springs, andprevent possible damagethatcould occur should therebe excessive axletochassis movement. Frontsuspension 1. Panhard rod 2. Radius arms 3. Coil springs 4. Shock absorber 5. Anti-roll bar
FRONTSUSPENSION 1 REPAIR SELF LOCKING NUTS WARNING: Whereselflocking nutsare removed, theymust bereplaced withnew nuts ofsame specification. PANHARD ROD Service repairno-60.10.07. Remove 1. Remove fixingsatmounting arm. 2. Remove fixingsataxle bracket. 3. Remove panhardrod. 4. Using asuitable lengthofsteel tubing, pressout flexible bushes. Ensuretubinglocates onouter edge ofbush andnotonrubber inner. Refit 5. Fitreplacement bushes. CAUTION:Applypressure toouter edgeof bush, andnotrubber inner. 6. Fitpanhard rodtoaxle bracket andmounting arm. Tighten fixingsto 88Nm (65lbf/ft). RADIUS ARM Service repairno-60.10.16. Remove 1. Loosen roadwheel retaining nuts. 2. Raise frontofvehicle. Support chassisonstands and remove wheel. 3.Support frontaxleweight withjack. 4. Remove radiusarmtochassis sidemember fixings. 5. Disconnect trackrodatball joint.