service LAND ROVER DEFENDER 1996 Workshop Manual

60FRONT SUSPENSION
2
REPAIRREV: 05/99
6.Remove fixings, radius arm to axle.
7.Lower radius arm front end to clear axle and
remove from vehicle.
8.Using suitable length of steel tubing, press out
flexible bushes.
Refit
9.Press in replacement bushes.
CAUTION: When pressing in new bushes
press on outer edge of bush and not
rubber inner.
10.Fit radius arm to axle mounting.
11.Fit track rod at ball joint.
12.Fit radius arm to chassis. Tighten bolts to
176
Nm (130 lbf/ft).
13.Fully tighten radius arm to axle fixings to197 Nm
(145 lbf/ft).
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 SHOCK ABSORBER
Service repair no - 60.30.02.
Remove
1.Loosen road wheel retaining nuts.
2.Support chassis on stands and remove road
wheel.
3.Support axle weight with jack.
4.Remove shock absorber lower fixing and
withdraw cupwasher, rubber bush and seating
washer.
5.Remove four shock absorber bracket fixings.
6.Withdraw shock absorber and bracket assembly.
7.Withdraw lower seating washer, rubber bush and
cupwasher.
8.Remove fixings, shock absorber to mounting
bracket.
9.Withdraw mounting bracket.
10.Lift off top seating washer, rubber bush and
cupwasher.

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
.

60FRONT SUSPENSION
4
REPAIR BUMP STOP
Service repair no - 60.30.10.
Remove
1.Remove fixings.
2.Remove bump stop.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray
.
Refit
3.Position bolts in slots in chassis brackets.
4.Fit bump stop, secure with washers and nuts.ANTI-ROLL BAR
Service repair no - 60.10.01
Remove
1.Mark for reassembly position of rubber bushes
on anti-roll bar.
2.Remove 4 nuts, bolts and washers securing both
anti-roll bar bush straps to chassis mounting
brackets.
3.Remove nuts, bolts, washers and rubber bushes
securing anti-roll bar to both links
4.Remove anti-roll bar.
Refit
5.Position bushes on anti-roll bar. Ensure split
points towards axle on RH bush and away from
axle on LH bush.
6.Fit anti-roll bar with two straps. To ensure correct
fit angled sides of bar should point down.
Loosely fit the bolts, washers and nyloc nuts.
7.Fit bolt, washers and rubber bushes. Using new
nuts fit anti-roll bar to links and tighten to
68Nm
(50 lbf/ft).
8.Tighten nuts securing straps to30Nm (22lbf/ft).

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).

REAR SUSPENSION
1
REPAIR REV: 05/99 REAR ROAD SPRING
Service repair no - 64.20.01.
Remove
1.Loosen rear road wheel retaining nuts.
2.Support chassis on stands and remove wheels.
3.Support rear axle weight with jack.
4.Disconnect shock absorbers at one end.
5.Position coil spring compressor correctly on road
spring.
6.Compress spring evenly to facilitate removal.
7.Lower axle to free road spring from upper seat.
CAUTION: Avoid lowering axle further than
rear brake flexible hose will allow.
8.Remove spring retainer plate.
9.Withdraw road spring.
10.Collect spring seat.
Refit
11.Position spring seat on axle location.
12.Fit road spring into chassis location and, using a
turning motion, fit to spring seat.
13.Fit spring retainer plate. Tighten bolts to
14 Nm
(10 lbf/ft).
14.Secure shock absorber. Tighten fixing to37 Nm
(27 lbf/ft).
15.Fit road wheels, 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)
REAR SHOCK ABSORBER
Service repair no - 64.30.02.
Remove
1.Loosen road wheel retaining nuts.
2.Support chassis on stands. Remove road wheel
and support rear axle weight with jack.
3.Remove fixings and withdraw shock absorber
from axle bracket.
4.Remove upper fixings.
5.Withdraw shock absorber.
6.If required, remove mounting bracket
7.If required, remove mounting rubbers.
Refit
8.Position shock absorber and fit upper fixings.
9.Secure shock absorber with lower fixings to axle
bracket. Tighten upper and lower fixings to
37
Nm (27 lbf/ft).
10.Fit road wheels, 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)

64REAR SUSPENSION
2
REPAIR BUMP STOP
Service repair no - 64.30.15.
Remove
1.Remove fixings.
2.Remove bump stop.
Refit
3.Position bolts in slots in bracket.
4.Fit bump stop, secure with washers and nuts.SUSPENSION LINK - UPPER
Service repair no - 64.35.44.
Remove
1.Support rear of chassis on stands, allow axle to
hang freely.
2.Remove fixings, upper link bracket to frame.
3.Remove fixings, upper links to pivot bracket.
4.Remove upper link, complete with frame bracket.
5.Remove bolt.
6.Separate link from bracket.
Renew bush
7.Press out rubber bushes.
8.Fit bush centrally in housing.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.

REAR SUSPENSION
3
REPAIR Refit
NOTE: Do no fully tighten fixings until all
components are in position.
9.Secure link to frame bracket.
10.Fit upper link to pivot bracket.
11.Fit frame bracket to chassis mounting.
12.Fully tighten fixings to
176 Nm (130 lbf/ft).
SUSPENSION LINK - LOWER
Service repair no - 64.35.02.
Remove
1.Site vehicle on a ramp .
2.Alternatively, support vehicle on stands under
rear axle.
3.Remove lower link rear fixings.
4.Remove mounting bracket fixings at side
member bracket.
5.Remove lower link complete.
6.Remove locknut.
7.Remove mounting bracket from lower link.
Renew bush
8.Press out rubber bushes.
9.Fit bush centrally in housing.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
Refit
10.Fit mounting rubber to lowerlink.
11.Secure mounting rubber to chassis bracket, but
do not fully tighten locknut.
12.Fit lower link to axle mounting and secure fixing
to
176 Nm (130 lbf/ft).
13.Lower vehicle, allow axle to take up static laden
position, and fully tighten link chassis fixing to
176 Nm (130 lbf/ft).

64REAR SUSPENSION
4
REPAIR ANTI-ROLL BAR
Service repair no - 64.35.08
Remove
1.Note for reassembly, position of rubber bushes
on anti-roll bar.
2.Remove 4 nuts, bolts and washers securing both
anti-roll bar bush straps to chassis mounting
brackets.
3.Remove nuts, bolts, washers and rubber bushes
securing anti-roll bar to links.
4.Remove anti-roll bar.Refit
5.Position rubber bushes on anti-roll bar. Fit joint
towards axle.
6.Fit anti-roll bar with two straps. Ensure link arms
point down as shown. Loosely fit, bolts, washers
and new nyloc nuts.
7.Fit bolt, washers and rubber bushes. Fit anti-roll
bar to links and tighten to
68Nm (50 lbf/ft).
8.Tighten nuts securing straps to30Nm (22 lbf/ft).

REAR SUSPENSION
5
REPAIR ANTI-ROLL BAR LINKS
Service repair no - 64.35.24.
Remove
1.Remove 2 nuts, bolts, washers and rubber
bushes from links and lower anti-roll bar to clear
links.
2.Remove cotter pin and loosen castellated nut a
few turns.
3.Release link using special tool18G 1063Aas
shown.
4.Remove castellated nut and remove link.
Refit
5.Fit anti-roll bar link arm and castellated nut. Point
link arm down as shown. Tighten fixing 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 to
68Nm (50 lbf/ft).
SELF LEVELLING UNIT
Service repair no - 64.30.09
Remove
WARNING: The levelling unit contains
pressurised gas and MUST NOT be
dismantled. Repair is by replacement of
complete unit only.
1.Raise and support the vehicle under chassis and
use a jack to support weight of the axle.
2.Disconnect upper links at pivot bracket.
3.Ease up levelling unit lower gaiter and unscrew
lower ball joint at push rod using thin jawed
spanners.
4.Release webbing strap from the chassis.
5.Remove 4 nuts securing top bracket to chassis
and withdraw levelling unit complete with
bracket.
Renew levelling unit ball joints
The ball joints for the levelling unit may be dismantled
for cleaning and examination.
6.Unscrew lower ball joint from pivot bracket.
7.Unscrew ball joint from top bracket.
8.Reassemble ball joints, packing with
Dextagrease G.P. or equivalent. Renew joints if
worn.
9.Check condition of gaiters and renew if
necessary.

BRAKES
1
REPAIR GENERAL BRAKE SERVICE PRACTICE
Brake fluid precautions
WARNING: Do not allow brake fluid to
come into contact with eyes or skin.
CAUTION: Brake fluid can damage
paintwork, if spilled wash off immediately
with plenty of clean water.
CAUTION: Use only correct grade of brake
fluid. If an assembly fluid is required use
ONLY brake fluid. Do NOT use mineral oil,
i.e. engine oil etc.
CAUTION: Thoroughly clean all brake
calipers, pipes and fittings before
commencing work on any part of the brake
system. Failure to do so could cause foreign
matter to enter the system and cause damage to
seals and pistons which will seriously impair the
efficiency of the brake system. To ensure the
brake system efficiency is not impaired the
following warnings must be adhered to :-
·DO NOT use any petroleum based cleaning
fluids or any proprietary fluids containing
petrol.
·DO NOT use brake fluid previously bled from
the system.
·DO NOT flush the brake system with any fluid
other than the recommended brake fluid.
The brake system should be drained and flushed
at the recommended service intervals.
Cover all electrical terminals carefully to make
absolutely certain that no fluid enters the
terminals and plugs.FLUID LEVEL CHECK/TOP UP
WARNING: Clean reservoir body and filler
cap before removing cap. Use only fluid
from a sealed container.
1.Park vehicle on level ground.
2.Check level is between 'MIN' and 'MAX' marks.
3.If level is below 'MIN' mark top up fluid level to
'MAX' mark on reservoir, using correct fluid.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
CAUTION: Do not fill reservoir above
maximum line.