LAND ROVER DEFENDER 1996 Workshop Manual

REAR SUSPENSION
1
DESCRIPTION AND OPERATION DESCRIPTION
The rear suspension design locates the rear axle with
two round section steel lower link arms and a forged
'A' frame, upper link assembly. This system allows
maximum axle articulation and wheel travel while
maintaining roll stiffness and directional stability.
The link arm is secured by a single retaining nut to the
chassis mounting, comprising a rubber bushed
bracket, which is retained by three fixings. A ferrule
rubber bush with a single retaining bolt is used to
secure the link arm to its axle mounting.
The upper link assembly is located on the rear
differential housing by a pivot ball-pin assembly. Two
brackets bolted to the chassis crossmember support
both sides of the 'A' frame of the link assembly,
secured by single retaining bolts.A Boge Hydromat self levelling unit can be fitted, as
an option, on 110/130 models to give additional
support when the vehicle is used to carry heavier
loads.
Two rubber bearing bushes, with retaining straps,
secure the rear of the anti-roll bar, if fitted, to the
chassis mountings, while bushed links support the
front of the anti-roll bar to the axle.
Conventional long travel coil springs and hydraulic
shock absorbers are used to control body movement.
The shock absorbers are secured to chassis mounting
brackets and fabricated lower mountings welded to to
the rear axle. Retaining plates are used to secure the
coil springs to the axle mounting while fabricated
brackets, welded to the chassis, are used for the
upper spring location.
Rear axle suspension
1.'A' frame, upper link assembly
2.Lower link
3.Coil springs
4.Shock absorber

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.

64REAR SUSPENSION
6
REPAIR Refit
10.Ensure ball pin threads are clean and smear
Loctite grade CVX on ball pin threads.
11.Fit upper ball joint to levelling unit and secure
gaiter.
12.Fit top bracket complete with levelling unit to
chassis and secure with 4 nuts and tighten to
47
Nm (35 lbf/ft).
13.Fit levelling unit to lower ball joint and secure
gaiter.
14.Attach webbing strap to chassis cross member.
15.Fit upper links to the pivot bracket and retain
with 2 bolts and nuts but do not tighten at this
stage.
16.Remove jack in support of axle and support from
under chassis.
17.Allow suspension to settle and then tighten 2
bolts and nuts retaining upper links to pivot
bracket to
176 Nm (130 lbf/ft).

REAR 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................................................................................
Top link to mounting bracket 176.....................................................................
Bottom link to axle 176.....................................................................................
Bottom link to chassis 176...............................................................................
Top link bracket to rear cross member 47......................................................
Shock absorber to axle 37 N............................................................................

BRAKES
1
DESCRIPTION AND OPERATION DESCRIPTION
The mechanical components of the hydraulic braking
system consists of four piston caliper disc brakes at
the front and two piston caliper disc brakes at the rear.
Vented front brake discs are fitted as standard on
110/130 models, while 90 models have solid discs.
However, on 90 models with a heavy duty chassis,
vented front discs may also be fitted.A cable controlled parking brake operates a single
drum brake mounted on the output shaft of the
transfer gearbox and is completely independent of the
main braking system.
The basic hydraulic system involves 2 separate and
independent primary and secondary circuits which
permits a degree of braking should a fault occur in
one of the circuits. The primary circuit operates the
rear brake calipers and the secondary circuit the front
brake calipers.
Master cylinder components
1.Secondary plunger
2.Secondary spring
3.Recuperation seal4.Primary spring
5.Recuperation seal
6.Primary plunger

70BRAKES
2
DESCRIPTION AND OPERATION REV: 05/99 OPERATION
Master cylinder
A tandem master cylinder, which is assisted by a light
weight, short, compact servo, is fed by a divided fluid
reservoir. The rear section supplies fluid for the
primary circuit and the front section the secondary
circuit.
When the brakes are off, the fluid can move
unrestricted between the dual line system and the
separate reservoirs in the fluid supply tank.
When the footbrake is applied, the primary plunger
assembly moves up the cylinder bore and the
pressure created acts in conjunction with the primary
spring to overcome the secondary springs, thus
moving the secondary plunger assembly up the bore.
At the same time initial movement of both plungers
takes the recuperating seals past the cut-off holes in
the cylinder chambers 'A' and 'C',see J6321, and
applies pressure to the fliud in those chambers, which
is directed to the respective circuits.
The fluid in chambers 'B' and 'D'is unaffected by
movement of the plungers and can move unrestricted
between the separate chambers and respective
reservoirs in the fluid supply tank, both before and
during brake application. When the brakes are
released, the plunger assemblies, aided by the return
springs are retracted faster than the fluid; this creates
a depression between the fluid in chambers 'A' and
'C'and the recuperation seals.
The recuperation seals momentarily collapse allowing
fluid in chambers 'B' and 'D'to flow through the holes
in the plungers, over the collapsed seals and into
chambers 'A' and 'C'respectively. The movement of
fluid from one set of chambers to the other, is
compensated for by fluid from the separate reservoirs
in the supply tank moving through the feed holes in
the cylinder. Conversely, the final return movement of
the plunger assemblies causes the extra fluid in
chambers 'A' and 'C'to move through the cut off holes
into the fluid reservoir.The servo unit provides controlled power assistance
to to the brake pedal when pressure is applied. Power
is obtained from a vacuum pump located on the RH
side of the engine cylinder block. The vacuum is
applied to both sides of a flexing diaphragm, and by
admitting atmosheric pressure to the rear diaphragm,
assistance is obtained. The servo unit is mounted
between the brake pedal and master cylinder and is
linked to these by push rods. Should a vacuum failure
occur, the two push rods will act as a single rod
allowing the brakes to function in the normal way,
although more effort will be required to operate the
brake pedal.
Hydraulic system
A brake fluid loss switch is fitted to the master cylinder
reservoir filler cap. The switch is wired to a warning
light on the vehicle fascia and will illuminate as a bulb
check when the ignition is switched on and
extinguishes when the engine is running and the
handbrake is released. A hydraulic failure in the
system will result in fluid loss, causing the warning
light to illuminate.
On 90 models a pressure reducing valve (PRV), fitted
to the RH bulkhead in the engine compartment,
maintains the braking balance, see J6322. Pressure
to the rear calipers is regulated by the PRV, this valve
is of the failure by-pass type, allowing full system
pressure to the rear brake calipers in the event of a
front (secondary) circuit failure.
NOTE: In some countries, a pressure
reducing valve may be fitted to 110 models
to conform to legal requirements.