LAND ROVER DEFENDER 1996 Workshop Manual

WHEELS AND TYRES
5
REPAIR Off Vehicle Balancing
Balance wheel assembly referring to equipment
manufacturer's instructions.
It is essential that the wheel is located by the centre
holeNOTthe stud holes. To ensure positive wheel
location the diameter of the locating collar on the
machine shaft must be 112,80 to 112,85 mm (4.441 to
4.443 in). This diameter will ensure that the collar fits
correctly within the centre hole of the wheel.
Where possible, always use the vehicle wheel
retaining nuts to locate the wheel on the balancer, to
avoid damaging the wheel. If this is not possible, the
locating nuts must be of a similar pattern to the
original wheel nuts. The use of conical type wheel
nuts for this purpose may damage the surface on alloy
wheels.
Cleaning
Wash the aluminium wheels using a suitable wash
and wax concentrate, correctly diluted and rinse with
cold clear water.DO NOTuse abrasives or aluminium
wheel cleaners containing acid, as they will destroy
the lacquer finish.
Tyre changing
Use only tyre changing equipment to mount or
demount tyres, following the equipment
manufacturer's instructions.DO NOTuse hand tools
or tyre levers, as they may damage tyre beads or the
wheel rim.
Puncture repair
Remove punctured tyre from wheel and repair using a
combination service plug and vulcanising patch.
Always follow manufacturer's instructions when using
a puncture repair kit.
Only punctures in tread area are reparable,DO NOT
attempt to repair punctures in tyre shoulders or
sidewalls.
Do not attempt to repair a tyre that has sustained the
following: bulges or blisters, ply separation, broken or
cracked beads, wear indicators visible and punctures
larger than 6 mm diameter.
CAUTION: Do not use tyre sealants that
are injected through valve stem to repair
punctured tyres, they may produce wheel
corrosion and tyre imbalance.
Aluminium wheel rim bead seats should be cleaned
using a non-abrasive cleaner to remove the mounting
lubricants and old rubber. Before mounting or
demounting a tyre, bead area should be well
lubricated with a suitable tyre lubricant.
TYRE FITTING
Alloy wheels
1.Install a new valve assembly.
2.Ensure wheel and tyre is adequately lubricated.
3.Mount tyre in normal manner. Inflate tyre and at
same time apply hand pressure to area around
valve to aid seating over valve first.
NOTE: Stop inflation immediately if tyre
seats opposite valve, as this will result in
valve being blocked by tyre beading,
making further inflation impossible, and carry out
following procedure.
4.Deflate tyre, unseat and rotate it around the rim
until valve is in line with that part of tyre which
seated initially. This part of beading having
seated over hump previously will automatically
seat first when tyre is re-inflated.
5.Inflate tyre to seat beads correctly, finally inflate
to correct pressure.

74WHEELS AND TYRES
6
REPAIRREV: 05/99 WHEELS
Remove
WARNING: The parking brake acts on
transmission, not rear wheels, and may
not hold vehicle when jacking unless
following procedure is used. If one front wheel
and one rear wheel is raised no vehicle holding or
braking effect is possible. Wheels MUST be
chocked in all circumstances.
Apply parking brake, select a gear in main
gearbox and engage low gear in transfer box.
1.Loosen 5 wheel nuts.
2.Using a suitable trolley jack, raise vehicle and
place on axle stands
See INTRODUCTION,
Information, Jacking
.
3.Remove wheel nuts and carefully withdraw
wheel over studs.
Refit
4.Ensure that retaining studs and nuts are clean.
5.Alloy wheels: Lightly coat wheel mounting spigot
face with a suitable anti-seize compound to
minimise possibility of adhesion between wheel
and spigot face.
6.Refit wheel taking care not to damage stud
threads. (Do not apply oil).
7.Fit wheel nuts and turn by hand for at least three
full threads before using any form of wheel
wrench.
8.Tighten nuts as much as possible using a
suitable wrench.
9.Lower vehicle and finally tighten nuts to correct
torque sequence shown.
Alloy wheels -
130 Nm (96 lbf/ft)
Steel wheels -100 Nm (80 lbf/ft)
Heavy duty wheels -170 Nm (125 lbf/ft)

WHEELS AND TYRES
7
REPAIR REV: 05/99 WHEEL STUD
Remove
1.Remove wheel
See Wheels.
2.Drive stud out of driveshaft flange.
Refit
3.Position stud in flange.
4.Install a suitable spacer over stud.
5.Using a M16 x 1.5 nut, a slave wheel nut is
suitable, pull stud into flange until shoulder of
stud abuts flange.
6.Refit wheel.
See Wheels

CHASSIS AND BODY
1
DESCRIPTION AND OPERATION CHASSIS AND BODY
Chassis
The chassis on all Defender variants are of the box
section, ladder type construction, manufactured from
2 mm (14swg) steel and treated with zinc phosphate,
cathodic electro coated, followed by waxing in the rear
crossmember.
Outriggers and angled brackets welded to the chassis
support suspension and axle components and are
also used as body mounting points. A detachable box
section crossmember, located between the two
chassis longitudinals is fitted to facilitate main gearbox
and tranfer box assembly removal.Should chassis damage occur, a comprehensive
range of components are available, including body
support outriggers, cross members and radius arm
mounting brackets. ALWAYS fit genuine parts that are
fully guaranteed and to original equipment
specification, fitted with Land Rover's BS 5135
welding standard.
Body
All body panels, with the exception of the fascia
bulkhead, are manufactured from aluminium alloy.
Galvanized steel is used for the front wheel arches to
give optimum protection. Most panels are also treated
with zinc phosphate and cathodic electro coated with
polyester surfacer, and are bolted to the welded
chassis.

76CHASSIS AND BODY
2
DESCRIPTION AND OPERATION LAND ROVER 90

CHASSIS AND BODY
3
DESCRIPTION AND OPERATION LAND ROVER 90
CHASSIS ALIGNMENT DIMENSIONS
A - Front Datum
B - Chassis Datum
C - Front axle centre line
D - Rear axle centre line
1.239,0 - 236,5 mm
2.82,0 - 79,5 mm
3.633 mm
4.2420,6 - 2418,6 mm
5.2306,4 - 2305,4 mm
6.981,2 - 978,7 mm
7.182,7 mm
8.41,5 - 37,0 mm
9.252 - 250 mm10.110 mm
11.2360mm - Wheelbase
12.636 - 634 mm
13.488 - 483 mm
14.488 - 483 mm
15.3431,1 - 3426,1 mm
16.588,3 - 586,3 mm
17.2313,8 - 2311,8 mm
18.590,5 mm
19.295,25 mm
20.519,60 - 517,00 mm
21.259,80 - 258,50 mm
22.1242,6 - 1240,6 mm
23.642,5 - 639,5 mm24.750,9 mm
25.439,5 - 436,5 mm
26.136,5 mm
27.299,5 - 295,5 mm
28.103 - 100 mm
29.131,5 - 126,5 mm
30.705,5 - 704,5 mm
31.705,5 - 704,5 mm
32.42,2 - 40,2 mm
33.491 - 486 mm
34.594,2 - 593,4 mm
35.283,0 - 282,2 mm
36.32,25 - 31,25 mm
37.397 - 395 mm

76CHASSIS AND BODY
4
DESCRIPTION AND OPERATION LAND ROVER 110

CHASSIS AND BODY
5
DESCRIPTION AND OPERATION LAND ROVER 110
CHASSIS ALIGNMENT DIMENSIONS
A - Front Datum
B - Chassis Datum
C - Front axle centre line
D - Rear axle centre line
1.4148 - 4143 mm
2.4009,5 - 4005 mm
3.978,7 - 981,2 mm
4.22 - 20 mm
5.252 - 250 mm
6.239 - 236,5 mm
7.3023,3 - 3022,3 mm
8.3030,7 - 3028,7 mm
9.155 - 153 mm
10.871,2 - 869,2 mm
11.2794 mm - Wheelbase
12.488 - 483 mm13.488 - 483 mm
14.82 - 79,5 mm
15.750,9 mm
16.750,9 mm
17.439,5 - 436,5 mm
18.439,5 - 436,5 mm
19.299,5 - 295,5 mm
20.500 - 495 mm
21.500 - 495 mm
22.594,2 - 593,4 mm
23.594,2 - 593,4 mm
24.283 - 282,2 mm
25.283 - 282,2 mm
26.1970 - 1968 mm
27.642,9 - 639,5 mm
28.750,9 mm29.290,5 mm
30.295,5 mm
31.299,5 - 295,5 mm
32.103 - 100 mm
33.1177,5 - 1175,5 mm
34.1692,5 - 1689,5 mm
35.2610 - 2606 mm
36.2040,5 - 2037,5 mm
37.1912,5 - 1909,5 mm
38.1359 - 1357 mm
39.1573 - 1571 mm
40.270 - 268 mm
41.665,5 - 663,5 mm
42.440 - 438 mm
43.32,25 - 31,25 mm

76CHASSIS AND BODY
6
DESCRIPTION AND OPERATION LAND ROVER 130

CHASSIS AND BODY
7
DESCRIPTION AND OPERATION LAND ROVER 130
CHASSIS ALIGNMENT DIMENSIONS
A - Front Datum
B - Chassis Datum
C - Front axle centre line
D - Rear axle centre line
E - Chassis Datum, section A - A
1.633,0 mm reference only
2.3569,3 - 3567,3 mm
3.2421,8 - 2419,8 mm
4.2317,5 - 2314,5 mm
5.2188,3 - 2185,3 mm
6.2119,5 - 2117,3 mm7.1990 - 1988 mm
8.1970 - 1968 mm
9.2401,8 - 2399,8 mm
10.110,0 mm reference
11.149,7 - 146,7 mm reference dimension
NOTE: The above dimensions are for the Land Rover 130 chassis frame. For additional
measurements, refer to the Land Rover 110 chassis frame drawing and aligment dimensions.