Land Rover Defender Workshop Rover Manual

							60FRONT
SUSPENSION
2 REPAIR
REV:09/97
6.Remove fixings,radiusarmtoaxle.
7. Lower radiusarmfront endtoclear axleand
remove fromvehicle.
8. Using suitable lengthofsteel tubing, pressout
flexible bushes.
Refit 9. Press inreplacement bushes.
CAUTION:Whenpressing innew bushes
press onouter edgeofbush andnot
rubber inner.
10. Fitradius armtoaxle mounting.
11. Fittrack rodatball joint.
12. Fitradius armtochassis. Tightenboltsto
176
Nm (130 lbf/ft).
13.Fully tighten radiusarmtoaxle fixings to197Nm
(145 lbf/ft).
14.Fitroad wheel, remove chassis standsandjack.
Tighten wheelnutstocorrect torque:
Alloy wheels -
130Nm(96lbf/ft)
Steel wheels -100Nm(80lbf/ft)
Heavy dutywheels -170Nm(125 lbf/ft)
FRONT SHOCK ABSORBER
Service repairno-60.30.02.
Remove 1. Loosen roadwheel retaining nuts.
2. Support chassisonstands andremove road
wheel.
3. Support axleweight withjack.
4.Remove shockabsorber lowerfixingand
withdraw cupwasher, rubberbushandseating
washer.
5. Remove fourshock absorber bracketfixings.
6.Withdraw shockabsorber andbracket assembly.
7. Withdraw lowerseating washer, rubberbushand
cupwasher.
8. Remove fixings,shockabsorber tomounting
bracket.
9. Withdraw mountingbracket.
10. Liftofftop seating washer, rubberbushand
cupwasher.    
						

							FRONTSUSPENSION
3
REPAIR
REV: 09/97
Refit
11. Assemble shockabsorber components.
12. Position shockabsorber, completewithbracket
and secure with4fixings.
13. Secure shockabsorber lowerfixing.
14. Fitroad wheel, remove chassis standsandjack.
Tighten wheelnutstocorrect torque:
Alloy wheels -
130Nm(96lbf/ft)
Steel wheels -100Nm(80lbf/ft)
Heavy dutywheels -170Nm(125 lbf/ft)
FRONT ROADSPRING
Service repairno-60.20.11.
Remove 1. Remove frontshock absorber
SeeFront
shock absorber
.
CAUTION: Avoidoverstretching brake
hoses. Ifnecessary, loosenhose
connector locknutstoallow hoses to
follow axle.
2. Lower axlesufficient tofree road spring.
3.Withdraw roadspring.
4. Withdraw shockabsorber bracketsecuring ring.
Refit 5. Fitshock absorber bracketretaining ring.Retain
in position withanut.
6. Position roadspring andraise axle.
7. Remove nutretaining securingring.
8. Fitfront shock absorber
SeeFront shock
absorber
.   
						

							60FRONT
SUSPENSION
4 REPAIR
BUMP
STOP
Service repairno-60.30.10.
Remove
1. Remove fixings.
2. Remove bumpstop.
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
.
Refit 3. Position boltsinslots inchassis brackets.
4. Fitbump stop,secure withwashers andnuts. ANTI-ROLL
BAR
Service repairno-60.10.01
Remove 1. Mark forreassembly positionofrubber bushes
on anti-roll bar.
2. Remove 4nuts, boltsandwashers securing both
anti-roll barbush straps tochassis mounting
brackets.
3. Remove nuts,bolts, washers andrubber bushes
securing anti-rollbartoboth links
4. Remove anti-rollbar.
Refit 5. Position bushesonanti-roll bar.Ensure split
points towards axleonRH bush andaway from
axle onLH bush.
6. Fitanti-roll barwith twostraps. Toensure correct
fit angled sidesofbar should pointdown.
Loosely fitthe bolts, washers andnyloc nuts.
7. Fitbolt, washers andrubber bushes. Usingnew
nuts fitanti-roll bartolinks andtighten to
68Nm
(50 lbf/ft).
8.Tighten nutssecuring strapsto30Nm(22lbf/ft).   
						

							FRONTSUSPENSION
5
REPAIR
ANTI-ROLL
BARLINKS
Service repairno-60.10.04.
Remove 1. Remove 2nuts, bolts, washers andrubber
bushes fromballjoint links.
2. Remove cotterpinand loosen castellated nuta
few turns.
3. Release linkjoint using special tool18G 1063A
as shown.
4. Remove castellated nutand link.
Refit
5. Fitlink and castellated nut.Ensure balljoint link
arm points up.Tighten nutto
40Nm (30lbf/ft)
and fitnew cotter pin.
6. Align anti-roll bartolinks.
7. Fitbolts, washers andrubber bushes usingnew
self locking nutsandsecure anti-roll bartolinks.
Tighten fixingsto
68Nm (50lbf/ft).   
						

							FRONTSUSPENSION
1
SPECIFICATIONS,
TORQUE
TORQUE
VALUES
NOTE:Torque wrenches shouldberegularly checkedforaccuracy toensure thatallfixings are
tightened tothe correct torque.
Nm
Anti-roll bar
- Strap nylocnuts 30
..............................................................................
- Ball linkself lock nut 68
........................................................................
- Castellated nut 40
................................................................................
Drag linktoaxle 40
.........................................................................................
Securing ringformounting turret 14
...............................................................
Radius armtochassis 176
...............................................................................
Panhard rodmounting armtochassis 88
.......................................................
Panhard rodtoaxle 88
....................................................................................
Panhard rodtomounting bracket 88
...............................................................
Tie bar toPanhard rod 110
..............................................................................
Radius armtoaxle 197
....................................................................................  
						

							REARSUSPENSION
1
DESCRIPTION
ANDOPERATION
DESCRIPTION The
rear suspension designlocates therear axle with
two round section steellower linkarms andaforged
A frame, upperlinkassembly. Thissystem allows
maximum axlearticulation andwheel travelwhile
maintaining rollstiffness anddirectional stability.
The linkarm issecured byasingle retaining nuttothe
chassis mounting, comprising arubber bushed
bracket, whichisretained bythree fixings. Aferrule
rubber bushwithasingle retaining boltisused to
secure thelink arm toits axle mounting.
The upper linkassembly islocated onthe rear
differential housingbyapivot ball-pin assembly. Two
brackets boltedtothe chassis crossmember support
both sides ofthe Aframe ofthe link assembly,
secured bysingle retaining bolts. A
Boge Hydromat selflevelling unitcan befitted, as
an option, on110/130 modelstogive additional
support whenthevehicle isused tocarry heavier
loads.Two rubber bearing bushes, withretaining straps,
secure therear ofthe anti-roll bar,iffitted, tothe
chassis mountings, whilebushed linkssupport the
front ofthe anti-roll bartothe axle.
Conventional longtravel coilsprings andhydraulic
shock absorbers areused tocontrol bodymovement.
The shock absorbers aresecured tochassis mounting
brackets andfabricated lowermountings weldedtoto
the rear axle. Retaining platesareused tosecure the
coil springs tothe axle mounting whilefabricated
brackets, weldedtothe chassis, areused forthe
upper spring location.
Rearaxlesuspension
1. Aframe, upperlinkassembly
2. Lower link
3. Coil springs
4. Shock absorber   
						

							REARSUSPENSION
1
REPAIR
REV: 09/97
REAR
ROAD SPRING
Service repairno-64.20.01.
Remove 1. Loosen rearroad wheel retaining nuts.
2. Support chassisonstands andremove wheels.
3.Support rearaxle weight withjack.
4. Disconnect shockabsorbers atone end.
5. Position coilspring compressor correctlyonroad
spring.
6. Compress springevenly tofacilitate removal.
7. Lower axletofree road spring fromupper seat.
CAUTION: Avoidlowering axlefurther than
rear brake flexible hosewillallow.
8. Remove springretainer plate.
9. Withdraw roadspring.
10. Collect springseat.
Refit 11. Position springseatonaxle location.
12. Fitroad spring intochassis location and,using a
turning motion, fitto spring seat.
13. Fitspring retainer plate.Tighten boltsto
14Nm
(10 lbf/ft).
14. Secure shockabsorber. Tightenfixingto37Nm
(27 lbf/ft).
15. Fitroad wheels, removechassis standsand
jack. Tighten wheelnutstocorrect torque:
Alloy wheels -
130Nm(96lbf/ft)
Steel wheels -100Nm(80lbf/ft)
Heavy dutywheels -170Nm(125 lbf/ft)
REAR SHOCK ABSORBER
Service repairno-64.30.02.
Remove 1. Loosen roadwheel retaining nuts.
2. Support chassisonstands. Remove roadwheel
and support rearaxle weight withjack.
3.Remove fixingsandwithdraw shockabsorber
from axlebracket.
4. Remove upperfixings.
5. Withdraw shockabsorber.
6. Ifrequired, removemounting bracket
7. Ifrequired, removemounting rubbers.
Refit 8. Position shockabsorber andfitupper fixings.
9. Secure shockabsorber withlower fixings toaxle
bracket. Tightenupperandlower fixings to
37
Nm (27lbf/ft).
10. Fitroad wheels, removechassis standsand
jack. Tighten wheelnutstocorrect torque:
Alloy wheels -
130Nm(96lbf/ft)
Steel wheels -100Nm(80lbf/ft)
Heavy dutywheels -170Nm(125 lbf/ft)    
						

							64REAR
SUSPENSION
2 REPAIR
BUMP
STOP
Service repairno-64.30.15.
Remove
1. Remove fixings.
2. Remove bumpstop.
Refit 3. Position boltsinslots inbracket.
4. Fitbump stop,secure withwashers andnuts. SUSPENSION
LINK-UPPER
Service repairno-64.35.44.
Remove 1. Support rearofchassis onstands, allowaxleto
hang freely.
2.Remove fixings,upperlinkbracket toframe.
3. Remove fixings,upperlinkstopivot bracket.
4. Remove upperlink,complete withframe bracket.
5. Remove bolt.
6. Separate linkfrom bracket.
Renew bush
7. Press outrubber bushes.
8. Fitbush centrally inhousing.
CAUTION: Applypressure toouter edgeof
bush, andnotrubber inner.    
						

							REARSUSPENSION
3
REPAIR
Refit
NOTE:
Donofully tighten fixingsuntilall
components areinposition.
9. Secure linktoframe bracket.
10. Fitupper linktopivot bracket.
11. Fitframe bracket tochassis mounting.
12. Fully tighten fixingsto
176Nm(130 lbf/ft).
SUSPENSION LINK-LOWER
Service repairno-64.35.02.
Remove 1. Site vehicle onaramp .
2. Alternatively, supportvehicleonstands under
rear axle.
3.Remove lowerlinkrear fixings.
4. Remove mounting bracketfixingsatside
member bracket.
5. Remove lowerlinkcomplete.
6. Remove locknut.
7. Remove mounting bracketfromlower link.
Renew bush
8. Press outrubber bushes.
9. Fitbush centrally inhousing.
CAUTION: Applypressure toouter edgeof
bush, andnotrubber inner.
Refit
10. Fitmounting rubbertolowerlink.
11. Secure mounting rubbertochassis bracket, but
do not fully tighten locknut.
12. Fitlower linktoaxle mounting andsecure fixing
to
176 Nm(130 lbf/ft).
13.Lower vehicle, allowaxletotake upstatic laden
position, andfully tighten linkchassis fixingto
176Nm(130 lbf/ft).    
						

							64REAR
SUSPENSION
4 REPAIR
ANTI-ROLL
BAR
Service repairno-64.35.08
Remove
1. Note forreassembly, positionofrubber bushes
on anti-roll bar.
2. Remove 4nuts, boltsandwashers securing both
anti-roll barbush straps tochassis mounting
brackets.
3. Remove nuts,bolts, washers andrubber bushes
securing anti-rollbartolinks.
4. Remove anti-rollbar. Refit
5. Position rubberbushes onanti-roll bar.Fitjoint
towards axle.
6. Fitanti-roll barwith twostraps. Ensure linkarms
point down asshown. Loosely fit,bolts, washers
and new nyloc nuts.
7. Fitbolt, washers andrubber bushes. Fitanti-roll
bar tolinks andtighten to
68Nm(50lbf/ft).
8.Tighten nutssecuring strapsto30Nm(22lbf/ft).