LAND ROVER DEFENDER 1996 Workshop Manual

76CHASSIS AND BODY
8
DESCRIPTION AND OPERATION CHASSIS FRAME ALIGNMENT
With the vehicle assembled, a check for chassis
squareness can be made as follows:
1.Place the vehicle on a level floor.
2.Mark measuring points at approximately the
locations shown in LR4412M ensuring that the
marks are exactly opposite on each side of the
chassis frame.3.Hold a plumb line against each of the measuring
points in turn and mark the floor directly beneath
the plumb-bob.
4.Move the vehicle and measure diagonally
between the marks made on the floor, if the
chassis is square the diagonals between the
related measuring points should agree within
9,50 mm.
5.Chassis frame dimensional checks can be
made, with the vehicle upper structure removed,
referring to the applicable illustration and
associated key.

CHASSIS AND BODY
1
REPAIR DOORS
RH rear door lock mechanism
RH front door lock mechanism

76CHASSIS AND BODY
2
REPAIR DOOR TRIM CASING
Service repair no - 76.34.01 - Front doors
Service repair no - 76.34.04 - Rear doors
Remove
1.Prise open finisher caps, remove 2 screws, and
detach door pull.
2.Remove single screw behind remote control
lever.
3.Prise off remote control lever bezel.
4.Prise off door locking button bezel.
5.Prise out window regulator handle centre
finisher, remove retaining screw, and withdraw
handle and bezel.
6.Using a screwdriver to release trim fasteners,
carefully ease trim casing from door.

CHASSIS AND BODY
3
REPAIR
Refit
7.Remove any trim fasteners held in door panel.
Refit or insert new clips to trim panel.
8.Ensure that anti-vibration pads are in position
and offer-up trim casing to door. Align fasteners
with holes in door and firmly push trim into
position.
9.Fit bezels to locking button and remote control
lever.
10.Fit single screw behind remote control lever.
11.Fit door pull and secure with 2 screws and
finisher caps.
12.Fit window regulator handle and retain with
single screw and finisher.WINDOW REGULATOR - REAR SIDE DOOR
Service repair no - 76.31.45
Remove
1.Remove door trim casing
See Door trim casing
.
2.Remove plastic sheet.
3.Temporarily fit handle, wind window up to its
fullest extent and support glass with a length of
timber, to prevent it falling when removing
regulator.
4.Remove 4 screws retaining regulator to
mounting panel and withdraw regulator whilst
sliding lifting arm button from lifting channel. To
assist this operation, remove timber and lower
glass.

76CHASSIS AND BODY
4
REPAIR
Refit
5.Insert lifting arm button into lifting channel.
6.Position regulator so that fixing holes line-up with
holes in mounting panel.
7.Secure with 4 screws and tighten evenly.
8.Temporarily fit handle and check that glass can
be raised and lowered smoothly without tight
spots.
9.Fit plastic sheet.
10.Fit door trim
See Door trim casing.EXTERIOR HANDLE - REAR SIDE DOOR
Service repair no - 76.58.02
Remove
1.Remove door trim casing
See Door trim casing
.
2.Peel back sufficient of plastic sheet to gain
access to handle mechanism.
3.Disconnect actuating rod from handle operating
lever.
4.Remove 2 screws and withdraw handle and
bezels.
Refit
5.Fit handle to door ensuring that both bezels are
in position - flat faces towards door and secure
with 2 screws.
6.Connect actuating rod to handle operating lever
and secure with spring clip.
7.Re-seal plastic sheet.
8.Fit door trim casing
See Door trim casing.

CHASSIS AND BODY
5
REPAIR SILL LOCKING BUTTON - REAR SIDE DOOR
Service repair no - 76.37.30
Remove
1.Remove door trim casing
See Door trim casing
.
2.Peel back sufficient of plastic sheet to reveal
mechanism.
3.Release spring clip securing button to operating
rod and withdraw rod from button.
4.Remove 2 screws securing button to door panel
and remove button.
Refit
5.Secure locking button assembly to door panel
with 2 screws.
6.Fit operating rod to button assembly and secure
with spring clip.
7.Re-seal plastic sheet and fit door trim casing
See Door trim casing.REMOTE CONTROL LEVER - REAR SIDE DOOR
Service repair no - 76.37.32
Remove
1.Remove door trim casing
See Door trim casing
.
2.Peel-back sufficient of plastic sheet to gain
access to remote lever.
3.Remove spring clip and disconnect control rod
from locking button.
4.Release spring clip and disconnect short locking
button control rod from latch mechanism.
5.Disconnect long remote control rod from latch
assembly.

76CHASSIS AND BODY
6
REPAIR 6.Remove 2 screws securing remote control lever
to mounting panel.
7.Release control rods from plastic retaining clips
located in mounting panel.
8.Withdraw remote control lever and rods from
door.
Refit
9.Fit plastic retaining clips to rod assembly into
position and secure with 2 screws.
10.Connect control rods to latch assembly and
secure with clips.
11.Fit plastic retaining rod clips to mounting panel.
12.Connect control rod to locking button and secure
with clip.
13.Re-seal plastic sheet and fit door trim casing
See Door trim casing.DOOR LATCH - REAR SIDE DOOR
Service repair no - 76.37.13.
Remove
1.Remove door trim casing
See Door trim
casing
.
2.Peel-back sufficient of plastic sheet to reveal
latch.
3.Release remote control lever rod from latch
assembly.
4.Disconnect door outer handle control rod from
latch assembly.
5.Disconnect door locking button remote control
rod from latch mechanism.
6.Remove 3 retaining screws and withdraw latch
assembly from door.
Refit
7.Fit latch assembly to door and secure with 3
screws, noting that uppermost screw is longer.
8.Connect remote control levers to latch
mechanism reversing instructions 3, 4 and 5.
9.Re-seal plastic sheet and fit door trim casing
See Door trim casing.

CHASSIS AND BODY
7
REPAIR DOOR GLASS - REAR SIDE DOOR
Service repair no - 76.31.02
Remove
1.Disconnect door check rod from door post.
2.Remove door trim casing
See Door trim casing
.
3.Remove plastic sheet.
4.Remove window regulator assembly
See
Window regulator - rear side door
.
5.Disconnect and remove door sill locking button
See Sill locking button.
6.Disconnect control rods from latch and door
outer handle mechanism.
7.Remove 4 screws retaining mounting panel to
door and remove panel, complete with rods and
control lever.
8.Remove single self tapping screw to remove
water channel.
9.Remove 2 screws and remove door check
torsion bar.
10.Remove door check rod by bending back end
stop to enable rod to be withdrawn.

76CHASSIS AND BODY
8
REPAIR
11.Remove 2 self-tapping screws from each side
and remove glass lower channels.
12.Remove inner and outer weather strips from
door sill.
13.Lower glass down to bottom of door, lift glass
over lower edge and withdraw from door.
14.Remove lift channel from glass, if necessary.Refit
15.Fit lift channel to new glass, if necessary.
16.Insert glass into lower channels and carefully
push glass up to top of frame.
17.Secure lower channels with 4 self-tapping
screws. Ensure that screw heads are screwed
down firmly below bottom of channels to prevent
damage to glass.
18.Fit door check rod and bend end stop back to
closed position.
19.Fit check stop torsion bar and secure with 2 nuts
and bolts.
20.Fit water channel and secure with single
self-tapping screw.
21.Fit mounting panel complete with rods and
remote control lever.
22.Connect control rods to latch and door outer
handle mechanism.
23.Fit door sill locking button and connect control
rod
See Sill locking button.
24.Fit window regulator
See Window regulator.
25.Fit door inner and outer sill wear strips.
26.Fit and re-seal plastic sheet.
27.Fit door trim casing
See Door trim casing.
28.Connect door check rod to door post.

CHASSIS AND BODY
9
REPAIR MOUNTING PANEL - FRONT DOOR
Service repair no - 76.11.28
Remove
1.Remove door trim casing
See Door trim
casing
and plastic sheet.
2.Remove 4 screws securing window regulator to
mounting panel.
3.Remove 5 screws securing mounting panel to
door frame.
4.Release remote control lever rod from latch
mechanism and from plastic clip in mounting
panel.
5.Slide window regulator arm from mounting panel
channel and remove panel with remote control
lever and rod.
Refit
6.Engage window regulator arm in mounting panel
channel.
7.Connect remote control rod to latch mechanism
and secure with clip.
8.Fit mounting panel and retain with 5 screws.
9.Secure window regulator to mounting panel with
4 screws.
10.Raise and lower window to check for free
movement.
11.Fit plastic sheet, and door trim casing
See
Door trim casing
.