lock LAND ROVER DEFENDER 1996 Workshop Manual

57STEERING
2
OVERHAUL 12.Remove piston, a bolt screwed into piston will
assist removal.
13.Remove input shaft dirt excluder.
14.Remove worm adjuster locknut using 'C' wrench
LRT-57-007.
15.Remove worm adjuster using wrench
LRT-57-006.
16.Tap splined end of shaft to free bearing.
17.Remove bearing cup and caged ball bearing
assembly.
18.Remove valve and worm assembly.
19.Remove inner bearing cage, cup and shim
washers. Retain shims for reassembly.
NOTE: Should difficulty be experienced
warm casing and bearing assembly. Cool
bearing cup using a mandrel and tap
steering box on a bench.Steering box seals
20.Remove circlip and seal from sector shaft
housing bore.
CAUTION: Do not remove sector shaft
bearings from casing. Replacement parts
are not available. If sector shaft bearings
are worn fit a new steering box.
21.Remove dirt excluder, circlip and seal from input
shaft housing bore.
CAUTION: The use of a seal puller is
recommended to prevent damage to
casing, and possible oil leaks.

STEERING
3
OVERHAUL
INSPECTING
Piston
22.Discard all rubber seals and obtain
replacements.
NOTE: A rubber seal is fitted behind
plastic ring on rack piston. Discard seal
and plastic ring.
Steering box casing
23.Examine piston bore for scoring and wear.
24.Examine feed tube.
25.Fit a new feed tube if damaged. Tighten union to
22 Nm (16 lbf/ft).
Sector shaft assembly
26.Check there is no side play on roller.
27.If side play on roller exists fit a new sector shaft.
28.Check condition of adjuster screw threads.
Check adjuster end float. Fit new adjuster if end
float exceeds 0.15 mm.
29.Examine bearing areas on shaft for excessive
wear.
30.Examine gear teeth for uneven or excessive
wear.
Sector shaft cover assembly
31.Inspect cover and bearing. If worn or damaged,
fit a new steering box.
Sector shaft adjuster locknut
32.The locknut is also a fluid seal. Fit new nut at
overhaul.

57STEERING
6
OVERHAUL
61.Fit new worm adjuster sealing ring.
62.Loosely screw adjuster into casing.
63.Fit locknut, do not tighten.
64.Turn in worm adjuster until end float is almost
eliminated. Ensure bearing cages are seated
correctly.
65.Measure maximum rolling torque of valve and
worm assembly, using a torque wrench and
spline socketLRT-57-025.
66.Turn in worm adjuster while rotating shaft to
increase figure measured to 0.56 Nm.67.Back off worm adjuster 1/4 turn. Turn in worm
adjuster to increase reading by 0.21 - 0.34 Nm
with locknut tight,
100 Nm (74 lbf/ft).Use worm
adjusting wrenchLRT-57-006and locknut
wrenchLRT-57-028.
Fitting rack and piston
68.Screw slave bolt into piston to aid assembly.
69.Fit piston and rack so piston is 70 mm (2.75 in)
from outer end of bore.
Fitting sector shaft
70.Fit sector shaft using seal saverLRT-57-021.
Align roller with cut out in casing as shown. Push
in sector shaft while rotating input shaft to allow
sector roller to engage worm.
Fitting rack adjuster
71.Fit rack adjuster and thrust pad to engage rack.
Back off half turn on adjuster.
72.Loosely fit new nylon pad and adjuster set screw
assembly.

STEERING
7
OVERHAUL Fitting sector shaft cover
73.Fit new sealing ring to cover.
74.Align cover with casing.
75.Screw cover assembly fully on to sector shaft
adjuster screw.
76.If necessary back off sector shaft adjuster screw.
Tap cover in place to allow cover to joint fully
with casing.
NOTE: Before tightening fixings, rotate
input shaft to ensure sector shaft roller is
free to move in valve worm. If initial
resistance is left, turn adjuster screw
approximately two turns in a clockwise direction.
77.Fit cover bolts. Tighten to
75 Nm (55 lbf/ft).
Fitting cylinder cover
78.Fit new square section seal to cover.
79.Remove slave bolt fitted at instruction 68. Press
cover into cylinder just to clear retainer ring
groove.
80.Fit retaining ring to groove with one end of ring
positioned 12 mm from extractor hole.
Adjusting sector shaft
NOTE: Refit drop arm and tighten nut
sufficiently to ensure that no backlash
exists between drop arm and sector shaft.
81.To set worm on centre, rotate input shaft to full
inner-lock (full right lock for a left hand drive
vehicle, full left lock for a right hand drive
vehicle). Rotate input shaft back towards centre
two full turns.
82.The box is now on centre and can be adjusted.
83.Hold input shaft and rock drop arm to establish
backlash is present. Continue rocking and slowly
turn sector shaft adjusting screw clockwise.
Continue rotating adjuster screw until backlash
has almost been eliminated.

57STEERING
8
OVERHAUL 84.Refit locknut and tighten.
NOTE: It is important steering box is
centralised before any adjustments are
made.
85.Check maximum rolling torque one and a quarter
turns either side of centre position, using a
torque wrench and spline socketLRT-57-025.
Rotate adjuster screw to obtain across centre
torque of 0.34 Nm plus torque figure at one and
a quarter turns. Tighten adjuster locknut to
60
Nm (44 lbf/ft).
Adjusting rack adjuster.
86.Turn in rack adjuster to increase figure
measured in instruction 85. by 0.23 - 0.34 Nm.
The final figure may be less, but must not
exceed 1.35 Nm.
87.Lock rack adjuster in position with grub screw.
Tighten to
5 Nm (4 lbf/ft).
Torque peak check
With input shaft rotated from lock to lock, rolling
torque figures should be greatest across centre
position and equally disposed about centre position.
The condition depends on value of shimming fitted
between valve and worm assembly inner bearing cup
and casing. The original shim washer value will give
correct torque peak position unless major components
have been replaced.
Procedure
88.With input coupling shaft toward the operator,
turn shaft fully counter-clockwise.
89.Check torque figures obtained from lock to lock
using torque wrench and spline socket
LRT-57-025.
90.Check also for equal engagement either side of
centre.Adjustments
91.Note where greatest figures are recorded
relative to steering position.If greatest figures are
not recorded across centre of travel (steering
straight-ahead), adjust as follows:
If torque peak occursbeforecentre position,addto
shim washer value; if torque peak occursaftercentre
position,subtractfrom shim washer value,
refer to
fitting valve and worm assembly
.
Shim washers are available as follows:
0.03mm, 0.07mm, 0.12mm and 0.24mm.
NOTE: Adjustment of 0.07mm to shim
value will move torque peak area by 1/4
turn on the shaft.
CAUTION: When reshimming valve and
worm, extreme caution must be exercised
to prevent seal damage during
reassembly.

STEERING
1
SPECIFICATIONS, TORQUE REV: 05/99 TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Ball joint nuts 40..............................................................................................
Clamp bolt nuts 9...........................................................................................
Steering column bracket nuts 22....................................................................
Steering wheel nut 43.....................................................................................
Tie bar to mounting nut 110.............................................................................
Universal joint pinch bolt 25............................................................................
PAS box
Adjuster locknut 60.................................................................................
Drop arm nut 176....................................................................................
Sector shaft cover to steering box 75.....................................................
Steering box to chassis 81.....................................................................
Steering box fluid pipes 14mm thread 15...............................................
Steering box fluid pipes 16mm thread 20...............................................
Tie bar 81...............................................................................................
PAS pump
High pressure fluid pipe 20.....................................................................
Power steering pump mounting 35.........................................................
Pulley bolts, power steering pump 10....................................................
Hose clamp 3........................................................................................
Front mounting plate bolts 9..................................................................
PAS reservoir
Hose clamp 3........................................................................................
* Torque values below are for all screws and bolts used except for those that are specified 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....................................................................................................

FRONT SUSPENSION
1
REPAIR SELF LOCKING NUTS
WARNING: Where self locking nuts are
removed, they must be replaced with new
nuts of same specification.
PANHARD ROD
Service repair no - 60.10.07.
Remove
1.Remove fixings at mounting arm.
2.Remove fixings at axle bracket.
3.Remove panhard rod.
4.Using a suitable length of steel tubing, press out
flexible bushes. Ensure tubing locates on outer
edge of bush and not on rubber inner.
Refit
5.Fit replacement bushes.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
6.Fit panhard rod to axle bracket and mounting
arm. Tighten fixings to
88 Nm (65 lbf/ft).
RADIUS ARM
Service repair no - 60.10.16.
Remove
1.Loosen road wheel retaining nuts.
2.Raise front of vehicle. Support chassis on stands
and remove wheel.
3.Support front axle weight with jack.
4.Remove radius arm to chassis side member
fixings.
5.Disconnect track rod at ball joint.

FRONT SUSPENSION
3
REPAIR REV: 05/99 Refit
11.Assemble shock absorber components.
12.Position shock absorber, complete with bracket
and secure with 4 fixings.
13.Secure shock absorber lower fixing.
14.Fit road wheel, remove chassis stands and jack.
Tighten wheel nuts to correct torque:
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)
FRONT ROAD SPRING
Service repair no - 60.20.11.
Remove
1.Remove front shock absorber
See Front
shock absorber
.
CAUTION: Avoid over stretching brake
hoses. If necessary, loosen hose
connector locknuts to allow hoses to
follow axle.
2.Lower axle sufficient to free road spring.
3.Withdraw road spring.
4.Withdraw shock absorber bracket securing ring.
Refit
5.Fit shock absorber bracket retaining ring. Retain
in position with a nut.
6.Position road spring and raise axle.
7.Remove nut retaining securing ring.
8.Fit front shock absorber
See Front shock
absorber
.

FRONT SUSPENSION
5
REPAIR ANTI-ROLL BAR LINKS
Service repair no - 60.10.04.
Remove
1.Remove 2 nuts, bolts, washers and rubber
bushes from ball joint links.
2.Remove cotter pin and loosen castellated nut a
few turns.
3.Release link joint using special tool18G 1063A
as shown.
4.Remove castellated nut and link.
Refit
5.Fit link and castellated nut. Ensure ball joint link
arm points up. Tighten nut to
40 Nm (30 lbf/ft)
and fit new cotter pin.
6.Align anti-roll bar to links.
7.Fit bolts, washers and rubber bushes using new
self locking nuts and secure anti-roll bar to links.
Tighten fixings to
68 Nm (50 lbf/ft).

FRONT SUSPENSION
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Anti-roll bar
- Strap nyloc nuts 30..............................................................................
- Ball link self lock nut 68........................................................................
- Castellated nut 40................................................................................
Drag link to axle 40.........................................................................................
Securing ring for mounting turret 14...............................................................
Radius arm to chassis 176...............................................................................
Panhard rod mounting arm to chassis 88.......................................................
Panhard rod to axle 88....................................................................................
Panhard rod to mounting bracket 88...............................................................
Tie bar to Panhard rod 110..............................................................................
Radius arm to axle 197....................................................................................