ground LAND ROVER DEFENDER 1996 User Guide

STEERING
1
ADJUSTMENT POWER STEERING BOX - ADJUST
Service repair no - 57.35.01
WARNING: Adjustments of steering box
should not be required while in warranty
period. If box is stiff or tight and within
warranty, it must be returned to manufacturer. No
attempt must be made to introduce backlash.
1.Apply park brake brake, chock wheels and Jack
up front of vehicle until wheels are clear of
ground.
2.Support chassis front on axle stands.
3.Disconnect drag link from steering drop arm.
4.Check torque to turn
See Fault diagnosis,
Stiff Steering Checklist
.
5.Centralise steering box
See Centralise
Steering Box
.
NOTE: Only check for no backlash when
steering box is in central position.
NOTE: If steering wheel is not straight, it
should be repositioned
See Repair,
Steering Wheel
.
6.Adjustment is obtained by rocking the drop arm
about centre whilst an assistant slowly tightens
the steering box adjuster screw.
7.Tighten locknut when all backlash has been
removed.8.Repeat the check for backlash. If backlash exists
loosen locknut and repeat adjustment
procedure.
9.Turn steering wheel lock to lock and check no
tightness exists.
10.Ensure front wheels are aligned and in straight
ahead position.
11.Adjust drag link 924 mm between ball joint
centres.
12.Connect drag link and tighten to
40 Nm (30
lbf/ft).
13.Lower vehicle to ground level and remove
chocks.
14.Road test vehicle
See Fault diagnosis, Road
Test Procedure
.
Drag link adjust
1.RH drive vehicles - if steering wheel is to right,
drag link is too long. If steering wheel is to left
drag link is too short.
LH drive vehicles - if steering wheel is to right,
drag link is too short. If steering wheel is to left
drag link is too long.
2.Adjust drag link until steering wheel points
straight ahead when vehicle is travelling in a
straight line.
CENTRALISE STEERING BOX
Service repair no - 57.35.05
LH drive vehicle
1.Disconnect drag link from drop arm
See Repair,
Drag link and drag link ends
.
2.Turn steering wheel on full RH lock.
3.Turn steering wheel back exactly two turns.
4.Fit drag link
See Repair, Drag link and drag
link ends
.
RH drive vehicle
1.Repeat operation for LH drive vehicle but turn
steering wheel on full LH lock.

STEERING
3
ADJUSTMENT FRONT WHEEL ALIGNMENT
Service repair no - 57.65.01
Checking Toe-out dimensions
NOTE: Recognised front wheel alignment
and tracking equipment should be used
for this operation. Only the use of basic
equipment is described below. No Adjustment is
provided for castor, camber or swivel pin
inclinations.
1.Set vehicle on level ground with road wheels
positioned straight ahead.
2.Push vehicle back and forwards to settle linkage.
3.Set up the equipment to manufacturers
instructions and check alignment as advised by
equipment supplier.
4.Position trammel probes on inner face of wheel,
not the rims, if the latter are damaged.
5.Measure toe-out at horizontal centre-line of
wheels.
6.Check tightness of clamp bolt fixings. Tighten to
14 Nm (10lbf/ft).
Adjust
7.Slacken clamps at both ends of track rod.
8.Rotate track rod to increase or decrease its
effective length until correct toe-out is obtained
See GENERAL SPECIFICATION DATA,
Information, Steering
.
9.Push vehicle rearwards turning steering wheel
from side to side to settle ball joints. With road
wheels set in straight ahead position, push
vehicle forward a short distance.
10.Recheck track and adjust if necessary.
11.When alignment is correct, tap ball joints in
direction of arrows to maximum of travel, to
ensure full unrestricted movement of track rod.
12.Tighten clamp bolts to
14 Nm (10 lbf/ft).
POWER STEERING PUMP DRIVE BELT
Service repair no - 57.20.01
Adjust
NOTE: For details of drive belt adjust
procedure.
See ELECTRICAL, Repair,
Auxiliary Drive Belt

STEERING
5
REPAIR REV: 05/99
23.Fit panhard rodSee FRONT SUSPENSION,
Repair, Panhard rod
.
24.Fit road wheels. Lower vehicle to ground and
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)
25.Remove plugs and refit feed and return pipes to
steering box. Tighten 16mm thread to
20 Nm (15
lbf/ft),
14mm thread to15 Nm (11 lbf/ft).
26.Remove filler cap. Fill reservoir to oil level mark
on dipstick, using recommended fluid
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
.
27.Bleed power steering system
See Power
steering system - bleed
.
28.Recheck fluid level and replace cap.
29.With engine running, test steering system for
leaks by holding steering in both full lock
directions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute, to avoid oil overheating and
possible seal damage.
30.Test drive vehicle: using both full lock directions,
to settle steering components. If possible, drive
vehicle over uneven ground and include harsh
braking.
WARNING: Do not test drive vehicle on
public highway.
31.Drive vehicle in a straight line on level ground
and stop.
32.Tighten tie bar to mounting nut to
110 Nm (81
lbf/ft).
33.Tighten tie bar to steering box fixings to81 Nm
(60 lbf/ft).
34.Ensure steering wheel is correctly aligned when
wheels are positioned straight ahead.
35.If necessary, reposition steering wheel
See
Steering wheel
.
36.Road test vehicle.

57STEERING
12
REPAIR STEERING DAMPER
Service repair no - 57.55.21
Remove
1.Park vehicle on level ground and chock rear
wheels.
2.Raise vehicle and locate axle stands or use a
ramp.
3.Remove bolt securing steering damper to drag
link bracket.
4.Remove retaining nuts, washers and rubber
bush securing damper to chassis mounting.
5.Withdraw damper.
6.Check rubber bushes and washers, renew if
necessary.Refit
7.Ensuring rubber bushes and washers are
correctly positioned, fit steering damper to
chassis mounting.
8.Fit damper to drag link bracket.
9.Remove axle stands or vehicle from ramp.

STEERING
13
REPAIR REV: 05/99 TRACK ROD AND LINKAGE
Service repair no - 57.55.09
Remove
1.Park vehicle on level ground and chock rear
wheels.
2.Raise vehicle and locate axle stands or use a
ramp.
3.Centralise steering
See Adjustment,
Centralise steering box
.
4.Unscrew 2 bolts and remove track rod protection
bracket from axle differential housing.
5.Remove split pin and castellated nut securing
track rod to swivel housing arms.
6.Disconnect track rod ball joints using
LRT-57-018.
7.Remove track rod.
8.Slacken clamp bolts.
9.Unscrew ball joints.

STEERING
15
REPAIR REV: 05/99 DRAG LINK AND DRAG LINK ENDS
Service repair no - 57.55.17
Remove
1.Park vehicle on level ground and chock rear
wheels.
2.Set road wheels in straight ahead position.
3.Raise vehicle and fit axle stands or use a ramp.4.Remove front road wheel.
5.Disconnect steering damper at drag link bracket.
6.Remove split pin and castellated nut securing
drag link ball joint to swivel housing arm.
7.Disconnect drag link ball joints using
LRT-57-018.
8.Remove drag link.
9.Slacken clamp bolts.
10.Unscrew ball joints and remove from drag link.
11.Clean internal threads of drag link.
12.Fit new ends to drag link and loosely fit clamp
bolts.
13.Set ball joints to drag link measurement to 28,5
mm.
14.Adjust ball pin centres to nominal length of 924
mm, this length is adjusted during refit.

FRONT SUSPENSION
1
DESCRIPTION AND OPERATION DESCRIPTION
The front suspension design allows maximum wheel
travel and axle articulation providing good ground
clearance without loss of traction or directional
stability.
Long radius arms are fitted to the front axle and
provide maximum axle articulation which is vital for off
road performance. The radius arms are secured to
fabricated mounting brackets welded to the front axle.
Flexible rubber bushes are used on a stem end joint
to secure the rear of the radius arms to mountings on
the chassis cross member.
A panhard rod, which ensures that the front axle
remains centrally located, is fitted transversely and
also uses ferrule rubber bush mountings at both axle
and chassis locations.Two rubber bearing bushes, with retaining straps,
secure the rear of the anti-roll bar to the chassis
mountings, while bushed links support the front of the
bar to the front axle.
Conventional long travel coil springs and hydraulic
shock absorbers are used to control body movement
in all conditions. The shock absorbers are secured to
fabricated towers which are bolted to the chassis. The
upper and lower fixings use a single location stud with
flexible rubber bushes, support washers and securing
nuts. Retaining plates are used to secure the coil
springs to the fabricated towers and axle mountings.
Rubber bump stops are fitted underneath the chassis,
adjacent to the front road springs, and prevent
possible damage that could occur should there be
excessive axle to chassis movement.
Front suspension
1.Panhard rod
2.Radius arms
3.Coil springs
4.Shock absorber
5.Anti-roll bar

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.

70BRAKES
16
REPAIRREV: 05/99 TRANSMISSION BRAKE SHOES
Service repair no - 70.45.18
Remove
1.Park vehicle on level ground, chock road wheels
and release handbrake. Alternatively, raise
vehicle on a ramp.
2.Disconnect rear propeller shaft from
transmission output flange at brake drum.
3.Slacken off transmission brake drum adjustment
bolt.
4.Remove single screw securing brake drum to
output flange.
5.Withdraw drum to expose brake assembly.
6.Release top and bottom springs from brake
shoes, see J6337.
7.Grip dished washer with a pair of pliers, depress
washer and turn through 90°.
8.Remove dished washer, complete with hold
down spring and pin from both shoes.
9.Move brake shoes out from adjuster slides,
release from abutment plate and remove from
backplate.
10.Check that springs are satisfactory for continued
use. If new brake shoes are to be fitted, the
srings should also be renewed.Refit
11.Locate RH brake shoe in slide and secure brake
shoe and lever assembly to backplate with hold
down pin, spring and dished washer.
12.Locate LH brake shoe in slide and fit abutment
plate between both brake shoes. Secure LH
shoe with hold down pin, spring and dished
washer.
13.Fit pull-off springs to brake shoes.
14.Fit brake drum. Tighten screw to
25 Nm (18
lbf/ft).
15.Check that hand brake lever is released.
16.Screw in and tighten adjuster bolt until brake
drum will not rotate by hand.
17.Tighten adjuster bolt to
25 Nm (18 lbf/ft)to
ensure brake drum is locked.
18.Slacken off adjuster bolt by 1.5 turns to give
shoes a running clearance. Check that the drum
is free to rotate.
19.Fit propeller shaft to output flange. Tighten
fixings to
46 Nm (34 lbf/ft).
20.Remove wheel chocks and check operation of
handbrake.

BRAKES
17
REPAIR HANDBRAKE CABLE
Service repair no - 70.35.25
Remove
1.Park vehicle on level ground, chock road wheels
and release handbrake. Alternatively, raise
vehicle on ramp.
2.Remove 3 trim studs and lift up handbrake
gaiter.
3.Remove split pin, clevis pin, washer and
disconnect cable from handbrake lever.
4.Slacken off transmission brake drum adjusting
screw.
5.Disconnect propeller shaft from output flange.
6.Remove retaining screw and withdraw brake
drum.
7.Release handbrake cable clevis from abutment
on cable lever, see J6337, and pull through
aperture in back plate.
8.Pull cable from heelboard and remove from
vehicle.
Refit
9.Feed new cable through heelboard ensuring
rubber grommet is correctly located.
10.Position cable over guide plate, insert through
backplate and connect to cable lever.
11.Fit cable to handbrake lever and secure with
clevis pin and split pin.
12.Fit handbrake gaiter.
13.Fit brake drum. Tighten screw to
25 Nm (18
lbf/ft).
14.Screw in and tighten adjuster bolt until brake
drum will not rotate by hand.
15.Tighten adjuster bolt further to
25 Nm (18 lbf/ft)
to ensure brake drum is locked.
16.Slacken off adjuster bolt by 1.5 turns to give
brake shoes running clearance. Check that the
drum is free to rotate.
17.Slacken locknut and adjust cable to give the
handbrake pawl two notches free movement on
the rachet before being fully operational on third
notch (brake shoes are fully expanded against
drum).
NOTE: Cable adjustment is for a new cable
or to compensate for cable stretch. Cable
adjustment must not be used to take up
brake shoe wear.
18.Fit propeller shaft to output flange. Tighten
fixings to
46 Nm (34 lbf/ft).
19.Remove wheel chocks and check operation of
handbrake.