oil level LAND ROVER DEFENDER 1996 Owner's Manual

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
.

STEERING
1
FAULT DIAGNOSIS INSUFFICIENT POWER ASSISTANCE
1.Is fluid level correct?
YES - go to 3.
NO - Fill/bleed sytem
2.Is problem a leak?
YES - Diagnose
See Power Steering Fluid
Leaks
.
NO - continue
3.Is drive belt tension correct?
YES - go to 5.
NO - Is drive belt worn or contaminated with oil?
See ELECTRICAL, Repair, Auxiliary drive
belt
.
4.Is problem resolved?
YES - end
NO - continue
5.Carry out pressure test at idle and 1000 rev/min.
See Power Steering System - Test.
6.Is correct pressure achieved?
YES - steering box defective
Not at any speed go to 9.
Not at idle go to 7.
7.Is idle speed correct?
YES-Goto8.
NO - Correct idle speed -
See ENGINE TUNING
DATA, Information, 300 Tdi Engine
.
8.Is problem resolved?
YES - end
NO - go to 9.
9.Bypass steering box using adaptor tap
LRT-57-001
10.Is correct pressure obtained?
YES - defective steering box
NO - defective steering pump
CAUTION: Do not hold steering wheel on
full lock for more than 30 seconds in any
one minute to avoid overheating fluid and
possibly damaging seals.
NOTE: 1. Excessive pressure in the
system is almost always caused by a
faulty relief valve in the PAS pump.
NOTE: 2. Insufficient pressure in the
system is usually caused by low fluid level
or PAS pump drive belt slip, or one of the
following: PAS system leaks, faulty PAS pump
relief valve, fault in steering box valve and worm
assembly, leak at piston in steering box, worn
components in PAS pump or box.

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
.

57STEERING
8
FAULT DIAGNOSIS 4. DIRECTIONAL STABILITY
From 1. GENERAL STEERING:
1.Is directional stability concern when vehicle is
towing?
YES - Check towing/vehicle loading parameters
in Owner's Handbook.
NO - go to 3.
2.Is problem resolved?
YES - end
NO - continue.
3.Check condition of rear trailing link/chassis
bushes.
4.Is problem resolved?
YES - end
NO - continue.
5.Check condition of front and rear shock
absorbers. If necessary, change units in pairs,
side to side.
6.Is problem resolved?
YES - end
NO - continue.
7.Check steering damper
See Steering Damper
.
8.Is problem resolved?
YES - end
NO - continue.
9.Check wheel balance
10.Is problem resolved?
YES - end
NO - contact local technical office.POWER STEERING FLUID LEAKS
1.Is fluid level correct?
YES - go to 3.
NO - Refill or drain to correct level. Bleed
system, check for leaks
See Repair, Power
Steering System - Bleed.
2.Is problem resolved?
YES - end
NO - continue.
3.Are hoses or joints leaking? Check on full lock
with engine at 2000 rev/min.
YES - loosen and retorque joints.
NO - go to 6.
4.Does leak remain?
YES - change PAS pipe.
NO - end.
5.Does leak remain?
YES - suspect seal in component. Check and
replace as necessary.
NO - end.
6.Is oil escaping from filler cap?
YES - bleed system
See Repair, Power
Steering System - Bleed.
NO - go to 8.
7.Is oil still escaping from filler cap?
YES - go back to 1.
NO - end.
8.Is oil leaking from PAS pump?
YES - go to 10.
NO - continue.
9.Is oil leaking from PAS box?
YES - go to 10.
NO - end.
10.Clean unit, add tracer dye to system. Retest
11.Is oil still leaking?
YES - establish leak point. Repair or replace unit
as necessary.
NO - end.

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.

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

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.

AIR CONDITIONING
3
ADJUSTMENT REFRIGERANT RECOVERY, RECYCLING,
RECHARGING
WARNING: The air conditioning system is
charged with a high pressure, potentially
toxic refrigerant. Repairs or servicing must
only be carried out by an operator familiar with
both the vehicle system and the charging and
testing equipment.
All operations must be carried out in a
well-ventilated area away from open flame and
heat sources.
Always wear safety goggles and gloves when
opening refrigerant connections.
WARNING: Wear eye and hand safety
protection. Open connections slowly in
case liquid or pressure is present. Allow to
bleed off slowly.
CAUTION: Overcharging air conditioning
system will cause excessive head
pressure.
An air conditioning portable Refrigerant Recovery
Recycling Recharging Station for use with R134a
refrigerant incorporates all the features necessary to
recover refrigerant R134a from the air conditioning
system, to filter and remove moisture, to evacuate and
recharge with the reclaimed refrigerant. The unit can
also be used for performance testing and air
conditioning system analysis.
The operator must adhere to the equipment
manufacturers' instructions.
Recovery and recycling
1.Connect a Refrigerant Station to the high and
low pressure servicing connections.
2.Operate the refrigerant recovery system
according to the manufacturers instructions.
3.Measure the amount of oil discharged from the
system. Add an equal amount of new refrigerant
oil to compressor before evacuation sequence.
WARNING: Refrigerant must always be
recycled before reuse, to ensure that the
purity of the refrigerant is high enough for
safe use in the air conditioning system. Recycling
should always be carried out with equipment
which is design certified by Underwriter
Laboratory Inc. for compliance with SAE-J1991.
Other equipment may not recycle refrigerant to
the required level of purity.
A R134a Refrigerant Recovery Recycling
Recharging Station must not be used with any
other type of refrigerant.
Refrigerant R134a from domestic and commercial
sources must not be used in motor vehicle air
conditioning systems.
Evacuation and recharging
1.Add refrigerant oil to compressor if necessary.
2.Renew the receiver/drier.
CAUTION: When a major repair has been
carried out, a leak test should be carried
out using inert gas.
3.Connect a Refrigerant Station to the high and
low pressure servicing connections.
CAUTION: Whenever the refrigerant
system is opened, the receiver/drier must
be renewed immediately before evacuating
and recharging the system.
4.Operate the refrigerant evacuation system
according to the manufactures instructions.
NOTE: If the vacuum reading is below
700mmHg after 15 minutes, suspect a leak
in the system. Partially recharge the
system and check for leaks using an electronic
leak tester. Check suction lines first, then run the
compressor for 5 minutes and then check the high
pressure lines.
CAUTION: The system must be Evacuated
immediately before recharging
commences. Delay between Evacuation
and Recharging is not permitted.