check oil LAND ROVER DEFENDER 1996 Owner's Manual

TRANSFER GEARBOX
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
Transfer gearbox
Pinch bolt - operating arm to crank arm 9......................................................
End cover gear change housing 9.................................................................
Bottom cover to transfer case 25....................................................................
Front output housing to transfer case 25........................................................
Cross shaft housing to front output housing 25...............................................
Gear change housing 25.................................................................................
Pivot shaft to link arm 25.................................................................................
Connecting rod to adjustable clevis 25...........................................................
Anti-rotation plate intermediate shaft 25.........................................................
Front output housing cover 25........................................................................
Pivot bracket to extension housing 25............................................................
Finger housing to front output housing 25......................................................
Bearing housing to transfer case 25...............................................................
Brake drum to coupling flange 25...................................................................
Bearing housing cover to transfer gearbox 45................................................
Rear output speedometer housing to transfer gearbox 45..............................
Selector finger to cross shaft high/low 25.......................................................
Selector fork, high/low to shaft 25...................................................................
Transmission brake to speedometer housing 72............................................
Gate plate to grommet plate 9.......................................................................
Gearbox to transfer case 45...........................................................................
Oil drain plug 30..............................................................................................
Oil filler/level plug 30.......................................................................................
Differential case (front to rear) 60...................................................................
Output flanges 162...........................................................................................
Differential case rear stake nut 72..................................................................
Transfer breather 15.......................................................................................
Transfer box front drive flange to drive shaft 45..............................................
Transfer box rear drive flange to drive shaft 45..............................................
Transfer gearbox mounting brackets to chassis 30........................................
Mounting brackets to transfer gearbox 55......................................................
Mounting rubbers to mounting brackets 21.....................................................

PROPELLER SHAFTS
1
FAULT DIAGNOSIS VIBRATION HARSHNESS
Check that the propeller shaft universal joints and
sliding splines are not siezed or worn and that the
shafts are correctly aligned.
NOTE: In the event that both shafts are
satisfactory, but the vibration/harshness is
still present, the transfer box operation
and balance of the road wheels should be
checked.
For transfer box operation
See TRANSFER
GEARBOX, Fault diagnosis, Transfer Gearbox -
Oil seal locations
.
For balance of road wheels
See WHEELS AND
TYRES, Repair, Wheel Balancing.

REAR AXLE AND FINAL DRIVE
1
FAULT DIAGNOSIS FAULT DIAGNOSIS
Complaint - Oil leaks
An external leak of lubrication from the hub seals can
be caused by a faulty internal seal. For example, if the
seals which separate the differential from the hubs are
faulty and the vehicle is operating or parked on an
embankment, oil from the differential may flood one
hub resulting in a lack of lubrication in the differential.
When a seal is found to be leaking check the axle
ventilation system, as a blockage can cause internal
pressure to force oil past the seals.
See 'Description and Operation' for illustrations of oil
seal locations.
When investigating hub seal leaks check the grease
for dilution with oil. Also check the differential oil level,
for signs of metal particles in the oil and the condition
of internal seals.
If the vehicle is driven in deep water with defective oil
seals, water may contaminate the lubricants and raise
the differential oil level, giving a false impression that
the housing has been overfilled.
Do not assume that a high oil level in the
differential is due to over filling or, that a low level
is because of an external leak.

REAR AXLE AND FINAL DRIVE
1
OVERHAUL DIFFERENTIAL ASSEMBLY - 110/130
Service repair no - 51.15.07
Overhaul
1.Drain off differential lubricating oil, and refit plug.
2.Remove rear axle assembly from vehicle
See
Repair, Rear axle
3.Remove hub driving member fixings.
4.Withdraw driving member and axle shaft
sufficiently to disengage differential.
5.Repeat instruction 4 for other axle shaft.
6.Remove fixings and support strip at differential
cover and withdraw cover and joint washer.
7.Note relationship marking on bearing caps and
axle casing to ensure correct refitting.
8.Remove fixings and withdraw differential bearing
caps.
9.Clean out and examine spreader tool pegholes
provided in gear casing face; ensure that holes
are free from dirt and burrs and damage.
10.Ensure that turnbuckle adjuster is free to turn.
Using axle spreader 18G31C
11.Fit axle spreader to engage peg holes.
(Spreader18G131C, Adaptor pegs18G131F)
12.Using a spanner, turn adjuster until all free play
between spreader and casing is taken up,
denoted by adjuster becoming stiff to turn.
13.Check that side members of spreader are clear
of casing.
14.Stretch casing, rotating adjuster by one flat at a
time, until differential assembly can be levered
out. Do not lever against spreader; use suitable
packing under levers to avoid damage to casing.

51REAR AXLE AND FINAL DRIVE
8
OVERHAUL 86.Before adjusting shim thickness, check pinion
face marking and if it has a plus (+) figure,
subtract that from shim thickness figure obtained
in previous instruction. Alternatively if pinion has
a minus (-) figure, add amount to shim thickness
figure.
87.Adjust shim thickness under pinion inner cup as
necessary, by amount determined in instructions
85 and 86.
88.Recheck pinion height setting instructions 82 to
84. If setting is correct, mean reading on dial
gauge will agree with figure marked on pinion
end face. For example, with an end face marking
of +3, dial gauge reading should indicate that
pinion is 0.003 in (0.0762 mm) below nominal.
89.When pinion setting is satisfactory, temporarily
remove pinion outer bearing.
90.Fit a new collapsable bearing spacer, flared end
outward, to drive pinion and refit outer bearing.
91.Fit pinion oil slinger.
92.Fit oil seal gasket.
93.Fit pinion oil seal, lipped side first, using general
purpose grease or, where available, a
molybdenum disulphide based grease on seal
lip, usingLRT-51-002to drift in seal.
94.Fit coupling flange and plain washer and loosely
fit a new flange nut. SecureLRT-51-003to
coupling flange, using slave fixings.
95.Alternately tighten flange nut and check drive
pinion resistance to rotation until following
figures are achieved, as applicable:
A.Assemblies re-using original pinion bearings:
17,3 to 34,5 kgf cm.
B.Assemblies with new pinion bearings: 34,5 to
46,0 kgf cm.
NOTE: Once the bearing spacer has
started to collapse the torque resistance
build-up is rapid, therefore check
frequently, using a spring balance, to ensure the
correct figures are not exceeded, otherwise a new
collapsable bearing spacer will be required.

REAR AXLE AND FINAL DRIVE
9
OVERHAUL Differential backlash checks
96.Pick up differential unit as left after instruction
52.
97.Fit differential unit and lever unit away from drive
pinion until opposite bearing cup is seated
against housing. Do not tilt unit.
98.Install a dial gauge on casing with its stylus
resting on back face of crown wheel. Zero the
gauge.
99.Lever differential unit to engage crown wheel
teeth in full mesh with drive pinion teeth. Do not
tilt unit.
100.Note total reading obtained on dial gauge.
101.From this figure subtract 0,25 mm to obtain
correct crown wheel backlash when fitted. The
result indicates value of shimming to be fitted
between differential case and bearing cone at
crown wheel side of differential.
102.Fit shim value determined in instruction 101,
taking shims from pack previously determined
during 'Differential bearing adjustment' checks,
instructions 57 to 62LRT-51-500details 1 and 2,
pressLRT-99-002, andLRT-51-504.
103.Fit remaining shims from instruction 101 to
opposite side of differential.LRT-51-501details
1 and 2, pressLRT-99-002, andLRT-51-504.
104.Fit differential unit with shims and bearings to
axle casing, using axle spreaderLRT-51-503
with pegs18G131F.
105.Remove axle spreader.106.Fit bearing caps in their correct position,
referring to relationship markings on caps and on
axle casing.
107.Tighten bearing caps fixings to
135 Nm (100
lbf/ft).
108.Mount a dial gauge on axle casing with stylus
resting on a crown wheel tooth.
109.Prevent drive pinion from rotating and check
crown wheel backlash which must be 0,15 to
0,27 mm. If backlash is not within specified
limits, repeat differential backlash checks,
instructions 96 to 102 looking for possible errors.
110.Fit differential cover and new gasket, coating
both sides of gasket with Hylomar PL 32M or an
equivalent non-setting sealant. Torque load for
fixings is
30 Nm (22 lbf/ft).
111.Reverse instructions 3 to 5 and coat threads of
hub driving member bolts with Loctite 'Studlock'
grade CVX and fit and tighten bolts evenly to
correct torque.
112.Fit rear axle assembly to vehicle
See Repair,
Rear axle
.
113.Replenish differential with recommended
lubricant
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
. After initial axle run,
check oil level and replenish as necessary to
filler/level plug hole.
114.Where major running parts have been replaced
during servicing, it is a recommended practice to
allow axle assembly to 'run in' by avoiding,
where possible, heavy loads and high speeds
during initial running.

FRONT AXLE AND FINAL DRIVE
1
FAULT DIAGNOSIS FAULT DIAGNOSIS
Complaint - Oil leaks
An external leak of lubrication can be caused by a
faulty internal seal. For example, if the seals which
separate the differential from the swivel housings are
faulty and the vehicle is operating or parked on an
embankment, oil may leak across the axle leaving one
swivel with a high level and the opposite swivel and
differential lacking lubrication.
See 'Description and Operation' for illustrations of oil
seal locations.
When investigating leaks or checking oil levels, it is
essential that all the lubrication is drained from any
housing with a high level and that the other levels are
checked.
Swivel oil should be checked for signs of grease
leaking from the hub bearings and oil contamination of
the hub grease.
Check that the axle ventilation system is clear, as a
blockage can cause internal pressure to force oil past
the seals.
If the vehicle is driven in deep water with defective oil
seals, water may contaminate the lubricants and when
checked, give a false impression that the housing has
been overfilled with oil.
Do not assume that a high oil level is due to over
filling or, that a low level is because of an external
leak.

FRONT AXLE AND FINAL DRIVE
5
OVERHAUL 38.Place retaining plate, joint washer and oil seal
over axle flange ready for assembly.
39.Fit swivel bearing housing to axle flange with 7
bolts. Tighten to
73 Nm (54 lbf/ft).
40.Grease and fit upper and lower swivel pin taper
roller bearings.
41.Position swivel pin housing over swivel bearing
housing.
42.Coat joint washer both sides with sealing
compound and position on lower swivel pin.
43.Loosely fit brake shield bracket plus lower swivel
pin with lug outboard to swivel pin housing.
44.Loosely fit top swivel pin plus existing shims and
brake hose bracket to swivel pin housing.
45.Apply Loctite 270 or equivalent to lower swivel
pin bolts.
78 Nm (58 lbf/ft),bend over lock tabs.
46.Tighten top swivel pin bolts to
78 Nm (58 lbf/ft).
Check and adjust preload on bearings
NOTE: Swivel housing oil seal and axle
should not be fitted.
47.Attach a spring balance to ball joint bore and pull
balance to determine effort required to turn
swivel pin housing.
Resistance, once initial inertia has been
overcome, should be1.16 to 1.46 kg.Adjust by
removing or adding shims to top swivel pin.
48.When setting is correct remove top swivel bolts,
apply Loctite 270 or equivalent. Refit bolts and
tighten to
78 Nm (58 lbf/ft),and bend over lock
tabs.
49.Apply recommended grease between lips of
swivel oil seal.50.Fit oil seal, joint washer and retaining plate with
7 bolts and spring washers. Tighten to
11 Nm (8
lbf/ft).
51.Fit tie rod and drag link and secure with new
cotter pins. Tighten fixing to
40 Nm (30 lbf/ft).
52.Fit brake disc shield.
53.Loosely fit lock stop bolt and nut.
54.Apply a recommended grease between lips of
swivel housing oil seal.
55.Secure oil seal with retaining plate and securing
bolts. Tighten to
11 Nm (8 lbf/ft).
56.Fit track-rod and drag link and secure with new
cotter pins.
57.Loosely fit lock stop bolt for later adjustment.
58.Fit brake disc shield.
Fit driveshaft and stub axle
59.Insert axle shaft, and when differential splines
are engaged, push assembly in fully.
CAUTION: Take care not to damage axle
shaft oil seals.
60.Place a new joint washer in position on swivelpin
housing to stub axle mating face. Coat threads
of stub axle bolts with Loctite 270.
61.Fit stub axle with flat at 12 O'clock position.
CAUTION: Ensure that constant velocity
joint bearing journal is butted against
thrust ring on stub axle before stub axle is
secured.
62.Place mud shield in position and secure stub
axle to swivel pin housing with 6 bolts and
tighten evenly to
65 Nm (48 lbf/ft).
63.Fit brake jump hoses to brake jump hose
bracket.
64.Fit complete front hub assembly
See Repair,
Front hub assembly
.
65.Check swivel pin housing oil drain plug is fitted.
66.Fill swivel assembly to correct level, with new oil
See SECTION 10, Maintenance, Under
vehicle maintenance
.
NOTE: On later vehicles fill swivel pin
housing with 0.33 Litres of Molytex EP 00
grease.
67.Set steering lock stop bolts
See STEERING,
Adjustment, Steering lock stops
.

FRONT AXLE AND FINAL DRIVE
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
FRONT AXLE
Hub driving member to hub 65*.......................................................................
Brake disc to hub 73.......................................................................................
Stub axle to swivel pin housing 65*.................................................................
Brake caliper to swivel pin housing 82............................................................
Upper swivel pin to swivel pin housing 78*.....................................................
Lower swivel pin to swivel pin housing 78*.....................................................
Oil seal retainer to swivel pin housing 11........................................................
Swivel bearing housing to axle case 73*.........................................................
Pinion housing to axle case 41.......................................................................
Crown wheel to differential housing 58...........................................................
Differential bearing cap to pinion housing 90..................................................
Differential drive flange to drive shaft 47.........................................................
Mudshield to bracket lower swivel pin 11........................................................
Bevel pinion nut 130........................................................................................
Draglink to hub arm 40....................................................................................
Panhard rod to axle bracket 88.......................................................................
Radius arm to axle 190....................................................................................
Radius arm to chassis side member 190.........................................................
NOTE: * These bolts to be coated with Loctite 270 prior to assembly.

57STEERING
4
FAULT DIAGNOSIS Symptom:-
Fluid leaks from steering box seals.
CAUTION: The steering wheel must not be
held on full lock for more than 30 seconds
in one minute, as this may overheat the
fluid and cause damage to the oil seals.
1.Check fluid level
See Repair, Power Steering
Fluid Reservoir
.
Check fluid pressure
See Power Steering
System - Test
.
2.Is pressure high?
YES - Renew pump
See Repair, Power
steering Pump
.
If oil seal leaks persist after renewing the pump
See Overhaul, Power Steering Box.
NO -
See Overhaul, Power Steering Box.
Symptom:-
Insufficient power assistance - castor return
action normal.
1.Are tyres correct type and pressure?
NO -
See GENERAL SPECIFICATION DATA,
Information, Wheels and Tyres
.
YES - Continue.
2.Is fluid level correct?
NO - Check fluid level
See Repair, Power
Steering Fluid Reservoir
.
YES - Check system for air locks
See Repair,
Power Steering System - Bleed
.
3.Is pressure correct?
NO - Check fluid pressure
See Power Steering
System - Test
.
If pressure is not correct after bleeding the
system, renew pump
See Repair, Power
Steering Pump
.
YES -
See Overhaul, Power Steering Box.Symptom:-
Steering heavy - stiff, poor castor return action.
1.Are tyres correct type and pressure?
NO -
See INTRODUCTION, Information,
Wheels and Tyres
.
YES - Check universal joints for seizure and
correct alignment
See Repair, Lower Steering
Shaft and Universal Joints
.
Check power steering box adjustments
See
Overhaul, Power Steering Box
.
2.Is the power assistance satisfactory?
NO - See fault symptomInsufficient
assistance, (castor return action normal).
YES - Disconnect drag link from drop arm and
check steering column and box for stiffness
See
Repair, Drag Link and Drag Link Ends
.
3.Is the steering stiff with the drag link
disconnected?
NO - Check steering ball joints for seizure and
axle swivels lubrication and resistance
See
Repair, Drag Link and Drag Link Ends
,See
FRONT AXLE AND FINAL DRIVE, Overhaul,
Front Stub Axle, Constant Velocity Joint and
Swivel Pin Housing
.
YES - Disconnect the lower steering shaft and
check the column and box for stiffness
See
Repair, Lower Steering Shaft and Universal
Joints
.
4.Is the steering column stiff to turn when
disconnected from the box?
NO - Remove and overhaul box
See Overhaul,
Power Steering Box
.
YES - Adjust steering column
See Stiff
Steering Checklist
.