service LAND ROVER DEFENDER 1996 Workshop Manual

CHASSIS AND BODY
5
REPAIR SILL LOCKING BUTTON - REAR SIDE DOOR
Service repair no - 76.37.30
Remove
1.Remove door trim casing
See Door trim casing
.
2.Peel back sufficient of plastic sheet to reveal
mechanism.
3.Release spring clip securing button to operating
rod and withdraw rod from button.
4.Remove 2 screws securing button to door panel
and remove button.
Refit
5.Secure locking button assembly to door panel
with 2 screws.
6.Fit operating rod to button assembly and secure
with spring clip.
7.Re-seal plastic sheet and fit door trim casing
See Door trim casing.REMOTE CONTROL LEVER - REAR SIDE DOOR
Service repair no - 76.37.32
Remove
1.Remove door trim casing
See Door trim casing
.
2.Peel-back sufficient of plastic sheet to gain
access to remote lever.
3.Remove spring clip and disconnect control rod
from locking button.
4.Release spring clip and disconnect short locking
button control rod from latch mechanism.
5.Disconnect long remote control rod from latch
assembly.

76CHASSIS AND BODY
6
REPAIR 6.Remove 2 screws securing remote control lever
to mounting panel.
7.Release control rods from plastic retaining clips
located in mounting panel.
8.Withdraw remote control lever and rods from
door.
Refit
9.Fit plastic retaining clips to rod assembly into
position and secure with 2 screws.
10.Connect control rods to latch assembly and
secure with clips.
11.Fit plastic retaining rod clips to mounting panel.
12.Connect control rod to locking button and secure
with clip.
13.Re-seal plastic sheet and fit door trim casing
See Door trim casing.DOOR LATCH - REAR SIDE DOOR
Service repair no - 76.37.13.
Remove
1.Remove door trim casing
See Door trim
casing
.
2.Peel-back sufficient of plastic sheet to reveal
latch.
3.Release remote control lever rod from latch
assembly.
4.Disconnect door outer handle control rod from
latch assembly.
5.Disconnect door locking button remote control
rod from latch mechanism.
6.Remove 3 retaining screws and withdraw latch
assembly from door.
Refit
7.Fit latch assembly to door and secure with 3
screws, noting that uppermost screw is longer.
8.Connect remote control levers to latch
mechanism reversing instructions 3, 4 and 5.
9.Re-seal plastic sheet and fit door trim casing
See Door trim casing.

CHASSIS AND BODY
7
REPAIR DOOR GLASS - REAR SIDE DOOR
Service repair no - 76.31.02
Remove
1.Disconnect door check rod from door post.
2.Remove door trim casing
See Door trim casing
.
3.Remove plastic sheet.
4.Remove window regulator assembly
See
Window regulator - rear side door
.
5.Disconnect and remove door sill locking button
See Sill locking button.
6.Disconnect control rods from latch and door
outer handle mechanism.
7.Remove 4 screws retaining mounting panel to
door and remove panel, complete with rods and
control lever.
8.Remove single self tapping screw to remove
water channel.
9.Remove 2 screws and remove door check
torsion bar.
10.Remove door check rod by bending back end
stop to enable rod to be withdrawn.

CHASSIS AND BODY
9
REPAIR MOUNTING PANEL - FRONT DOOR
Service repair no - 76.11.28
Remove
1.Remove door trim casing
See Door trim
casing
and plastic sheet.
2.Remove 4 screws securing window regulator to
mounting panel.
3.Remove 5 screws securing mounting panel to
door frame.
4.Release remote control lever rod from latch
mechanism and from plastic clip in mounting
panel.
5.Slide window regulator arm from mounting panel
channel and remove panel with remote control
lever and rod.
Refit
6.Engage window regulator arm in mounting panel
channel.
7.Connect remote control rod to latch mechanism
and secure with clip.
8.Fit mounting panel and retain with 5 screws.
9.Secure window regulator to mounting panel with
4 screws.
10.Raise and lower window to check for free
movement.
11.Fit plastic sheet, and door trim casing
See
Door trim casing
.

76CHASSIS AND BODY
10
REPAIR SILL LOCKING BUTTON - FRONT DOOR
Service repair no - 76.37.29
Remove
1.Remove door trim casing
See Door trim
casing
.
2.Peel back sufficient of plastic sheet to expose
mechanism.
3.Release spring clip and disconnect operating rod
from latch mechanism.
4.Remove 2 screws and withdraw locking button
assembly.
Refit
5.Secure locking button assembly to door with 2
screws.
6.Connect operating rod to latch mechanism and
secure with spring clip.
7.Re-seal plastic sheet and fit door trim casing
See Door trim casing.WINDOW REGULATOR - FRONT DOOR
Service repair no - 76.31.45
Remove
1.Remove door trim casing
See Door trim casing
.
2.Remove plastic sheet.
3.Temporarily fit handle, position window half open
and support with a length of timber.
4.Remove 2 lower screws securing mounting
panel to door and slacken 3 upper screws.
5.Remove 4 screws retaining window regulator to
mounting panel and slide operating arms from
channels attached to glass and mounting panel
and remove regulator.
Refit
6.Insert regulator operating arms into channels.
7.Fit and tighten mounting panel lower screws and
tighten upper screws.
8.Position holes in regulator to line-up with holes in
mounting panel and secure with 4 screws.
9.Temporarily fit regulator handle and check that
glass can be raised and lowered without tight
spots.
10.Secure plastic sheet.
11.Fit door trim casing
See Door trim casing.

CHASSIS AND BODY
11
REPAIR REMOTE CONTROL LEVER - FRONT DOOR
Service repair no - 76.37.31
Remove
1.Remove door trim casing
See Door trim
casing
.
2.Peel back sufficient of plastic sheet to gain
access to remote lever.
3.Release spring clip and disconnect control rod
from latch mechanism.
4.Release control rod from plastic clip in mounting
panel.
5.Remove 2 screws securing remote control lever
to mounting panel and withdraw lever and
control rod.Refit
6.Feed control rod into position and loosely secure
lever to mounting panel with 2 screws.
7.Connect control rod to latch mechanism and
secure with spring clip.
8.Tighten control lever retaining screws.
9.Secure control rod to plastic clip in mounting
panel.
10.Secure plastic sheet.
11.Fit door trim casing
See Door trim casing.

76CHASSIS AND BODY
12
REPAIR EXTERIOR HANDLE - FRONT DOOR
Service repair no - 76.58.01
Remove
1.Remove door trim casing
See Door trim
casing
.
2.Remove mounting panel
See Mounting panel
- front door
and support glass with timber.
3.Disconnect operating rod from handle
mechanism.
4.Disconnect rod from locking barrel lever.
5.Remove 2 screws and withdraw handle
assembly.Refit
6.Fit handle to door ensuring that two bezels are in
position - flat faces towards door, and secure
with 2 screws.
7.Connect rod to handle operating lever and
secure with spring clip.
8.Connect rod to locking barrel lever and retain
with spring clip.
9.Fit mounting panel
See Mounting panel - front
door
.

CHASSIS AND BODY
13
REPAIR LATCH ASSEMBLY - FRONT DOOR
Service repair no - 76.37.12
Remove
1.Remove mounting panelSee Mounting panel
and support glass with timber.
2.Disconnect control rod from handle operating
lever.
3.Disconnect control rod from locking lever on
handle.
4.Disconnect locking button control rod from latch
mechanism.
5.Remove 2 screws and remove handle assembly
from door.
6.Remove 2 self-tapping screws retaining lower
end of window glass runner.
7.Remove 3 screws securing latch assembly to
door.
8.Whilst taking care not to damage runner, ease
runner away from latch and manoeuvre latch
assembly from door.
Refit
9.Carefully ease window runner away, sufficiently
to enable latch to be located into position.
10.Secure latch to door with 3 screws.
11.Secure window runner with 2 screws ensuring
that packing strip is in position and that screw
heads are below bottom of runner to prevent
damage to glass.
12.Fit handle with 2 screws, ensuring that bezels
are in position.
13.Connect control rod to handle operating lever
and secure with spring clip.
14.Connect control rod to locking lever and retain
with spring clip.
15.Connect locking button control rod to latch lever
and secure with spring clip.
16.Fit mounting panel
See Mounting panel.

76CHASSIS AND BODY
14
REPAIR DOOR GLASS - FRONT DOOR
Service repair no - 76.31.01
Remove
1.Remove mounting panel
See Mounting panel
- front door
.
2.Remove window regulator.
3.Push glass up to top of its travel and support
with a suitable length of timber.
4.Remove 2 self tapping screws securing window
glass runner on latch side of door and single
screw from hinge side.
5.Taking care not to damage paint, prise exterior
waist weather strip from door.
6.Remove timber support and lower glass to
bottom of door.
7.Ease runner from glass at hinge side of door, lift
glass over bottom edge of door and withdraw.

CHASSIS AND BODY
15
REPAIR
Refit
8.Insert glass into runners at an angle as
illustrated.
9.Whilst lifting glass, position it squarely in
runners, raise to top of travel and insert timber
support.
10.Secure hinge side runner with single screw
ensuring that packing strip is in position.
11.Locate packing strip and secure opposite runner
with 2 screws. Ensure that all 3 screw heads are
well below bottom of runners to prevent damage
to glass.
12.Locate regulator in window lift channels.
13.Fit mounting panel
See Mounting panel - front
door
.LOCKING BARREL - FRONT DOOR
Service repair no - 76.37.39
Remove
1.Remove door trim casing
See Door trim
casing
and plastic sheet.
2.Remove mounting panel
See Mounting panel
- front panel
.
3.Raise and support glass to gain access to latch
mechanism.
4.Release spring clip and disconnect rod from lock
operating lever.
5.Remove single screw and withdraw lock lever
assembly.
6.Withdraw lock barrel from exterior door handle
complete with locking sleeve.