LAND ROVER DEFENDER 1996 Workshop Manual

76CHASSIS AND BODY
10
REPAIR SILL LOCKING BUTTON - FRONT DOOR
Service repair no - 76.37.29
Remove
1.Remove door trim casing
See Door trim
casing
.
2.Peel back sufficient of plastic sheet to expose
mechanism.
3.Release spring clip and disconnect operating rod
from latch mechanism.
4.Remove 2 screws and withdraw locking button
assembly.
Refit
5.Secure locking button assembly to door with 2
screws.
6.Connect operating rod to latch mechanism and
secure with spring clip.
7.Re-seal plastic sheet and fit door trim casing
See Door trim casing.WINDOW REGULATOR - FRONT 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, position window half open
and support with a length of timber.
4.Remove 2 lower screws securing mounting
panel to door and slacken 3 upper screws.
5.Remove 4 screws retaining window regulator to
mounting panel and slide operating arms from
channels attached to glass and mounting panel
and remove regulator.
Refit
6.Insert regulator operating arms into channels.
7.Fit and tighten mounting panel lower screws and
tighten upper screws.
8.Position holes in regulator to line-up with holes in
mounting panel and secure with 4 screws.
9.Temporarily fit regulator handle and check that
glass can be raised and lowered without tight
spots.
10.Secure plastic sheet.
11.Fit door trim casing
See Door trim casing.

CHASSIS AND BODY
11
REPAIR REMOTE CONTROL LEVER - FRONT DOOR
Service repair no - 76.37.31
Remove
1.Remove door trim casing
See Door trim
casing
.
2.Peel back sufficient of plastic sheet to gain
access to remote lever.
3.Release spring clip and disconnect control rod
from latch mechanism.
4.Release control rod from plastic clip in mounting
panel.
5.Remove 2 screws securing remote control lever
to mounting panel and withdraw lever and
control rod.Refit
6.Feed control rod into position and loosely secure
lever to mounting panel with 2 screws.
7.Connect control rod to latch mechanism and
secure with spring clip.
8.Tighten control lever retaining screws.
9.Secure control rod to plastic clip in mounting
panel.
10.Secure plastic sheet.
11.Fit door trim casing
See Door trim casing.

76CHASSIS AND BODY
12
REPAIR EXTERIOR HANDLE - FRONT DOOR
Service repair no - 76.58.01
Remove
1.Remove door trim casing
See Door trim
casing
.
2.Remove mounting panel
See Mounting panel
- front door
and support glass with timber.
3.Disconnect operating rod from handle
mechanism.
4.Disconnect rod from locking barrel lever.
5.Remove 2 screws and withdraw handle
assembly.Refit
6.Fit handle to door ensuring that two bezels are in
position - flat faces towards door, and secure
with 2 screws.
7.Connect rod to handle operating lever and
secure with spring clip.
8.Connect rod to locking barrel lever and retain
with spring clip.
9.Fit mounting panel
See Mounting panel - front
door
.

CHASSIS AND BODY
13
REPAIR LATCH ASSEMBLY - FRONT DOOR
Service repair no - 76.37.12
Remove
1.Remove mounting panelSee Mounting panel
and support glass with timber.
2.Disconnect control rod from handle operating
lever.
3.Disconnect control rod from locking lever on
handle.
4.Disconnect locking button control rod from latch
mechanism.
5.Remove 2 screws and remove handle assembly
from door.
6.Remove 2 self-tapping screws retaining lower
end of window glass runner.
7.Remove 3 screws securing latch assembly to
door.
8.Whilst taking care not to damage runner, ease
runner away from latch and manoeuvre latch
assembly from door.
Refit
9.Carefully ease window runner away, sufficiently
to enable latch to be located into position.
10.Secure latch to door with 3 screws.
11.Secure window runner with 2 screws ensuring
that packing strip is in position and that screw
heads are below bottom of runner to prevent
damage to glass.
12.Fit handle with 2 screws, ensuring that bezels
are in position.
13.Connect control rod to handle operating lever
and secure with spring clip.
14.Connect control rod to locking lever and retain
with spring clip.
15.Connect locking button control rod to latch lever
and secure with spring clip.
16.Fit mounting panel
See Mounting panel.

76CHASSIS AND BODY
14
REPAIR DOOR GLASS - FRONT DOOR
Service repair no - 76.31.01
Remove
1.Remove mounting panel
See Mounting panel
- front door
.
2.Remove window regulator.
3.Push glass up to top of its travel and support
with a suitable length of timber.
4.Remove 2 self tapping screws securing window
glass runner on latch side of door and single
screw from hinge side.
5.Taking care not to damage paint, prise exterior
waist weather strip from door.
6.Remove timber support and lower glass to
bottom of door.
7.Ease runner from glass at hinge side of door, lift
glass over bottom edge of door and withdraw.

CHASSIS AND BODY
15
REPAIR
Refit
8.Insert glass into runners at an angle as
illustrated.
9.Whilst lifting glass, position it squarely in
runners, raise to top of travel and insert timber
support.
10.Secure hinge side runner with single screw
ensuring that packing strip is in position.
11.Locate packing strip and secure opposite runner
with 2 screws. Ensure that all 3 screw heads are
well below bottom of runners to prevent damage
to glass.
12.Locate regulator in window lift channels.
13.Fit mounting panel
See Mounting panel - front
door
.LOCKING BARREL - FRONT DOOR
Service repair no - 76.37.39
Remove
1.Remove door trim casing
See Door trim
casing
and plastic sheet.
2.Remove mounting panel
See Mounting panel
- front panel
.
3.Raise and support glass to gain access to latch
mechanism.
4.Release spring clip and disconnect rod from lock
operating lever.
5.Remove single screw and withdraw lock lever
assembly.
6.Withdraw lock barrel from exterior door handle
complete with locking sleeve.

76CHASSIS AND BODY
16
REPAIR 7.To remove barrel from plastic retaining sleeve,
depess spring loaded button and withdraw
sleeve.
Refit
NOTE: If a new barrel is being fitted, check
that number on barrel coincides with
number on accompanying key.
8.Push plastic retaining sleeve over barrel until
spring loaded peg locks it into position.
9.Fit barrel and plastic sleeve assembly to locking
sleeve and insert into exterior handle reversing
instruction 6.
10.Assemble lock lever components as illustrated
and from inside of door panel, fit them to barrel
assembly with single screw.
11.Connect operating rod to lock lever and secure
with spring clip, reversing instruction 4.
12.Fit mounting panel
See Mounting panel - front
door
.DOOR STRIKER - ADJUST
Service repair no - 76.37.23 - front door
Service repair no - 76.37.24 - rear door, 110/130
Adjust
1.Loosen 2 Torq bolts securing striker to body.
2.Adjust alignment of striker vertically and
horizontally, lightly tighten bolts.
3.Close door, check for correct latching with door
lock and for centering on striker.
4.Add or remove packing shims as necessary
behind striker and fully tighten bolts.
5.Carry out further adjustment as necessary. If full
adjustment is not achieved carry out the
following:
6.Remove striker and nut plate.
7.Elongate striker bolt holes in 'B' or 'C' post in
direction required.
8.Refit striker and adjust as necessary.

CHASSIS AND BODY
17
REPAIR REAR SEAT CUSHION - 90
Service repair no - 78.10.18/99
Remove
1.Release seat cushion stowage strap.
2.Remove 4 bolts and spring washers and lift seat
cushion from pivot brackets.
3.Remove 4 bolts, plain washers, spring washers
and nuts. Detach both pivot brackets from wheel
arch.
Refit
4.Secure pivot brackets to wheel arch and tighten
bolts to
10 Nm (7 lbf/ft).
5.Position seat cushion in pivot brackets and
secure with 4 bolts and spring washers.
6.Fit stowage strap.REAR SEAT SQUAB - 90
Service repair no - 78.10.58/99
Remove
1.Release seat cushion stowage strap and lower
seat cushion.
2.Slacken 2 bolts securing seat squab brackets to
body side.
3.Remove 2 bolts, plain washers, spring washers
and nuts securing seat squab to wheel arch.
4.Lift seat squab and release brackets from
retaining bolts.
Refit
5.Lower seat squab brackets over retaining bolts,
tighten bolts to
10 Nm (7 lbf/ft).
6.Secure seat squab to wheel arch, tighten bolts to
10 Nm (7 lbf/ft).
7.Raise seat cushion and fit stowage strap.

76CHASSIS AND BODY
18
REPAIR REAR BENCH SEAT
Service repair no - 78.10.57/99
Remove
1.Remove rear bench seat cushion.
2.Remove 4 bolts securing seat frame to body and
collect spacers and brackets containing captive
nuts.
3.Remove screw securing rear end of squab to
body.
4.Remove rear bench seat.Refit
5.Position rear bench seat to body.
6.Position bracket and spacers, and loosely fit
bolts securing front end of cushion frame to
body.
7.Loosely fit bolts securing rear end of cushion
frame to body while second person holds
bracket in position from under vehicle.
8.Fit screw securing squab to body.Tighten to
10
Nm (7 lbf/ft).
9.Tighten cushion frame to body bolts to10 Nm (7
lbf/ft).
10.Fit bench seatcushion.

CHASSIS AND BODY
19
REPAIR FRONT SEAT BELTS
Service repair no - 76.73.13
Remove
1.Remove plastic seat belt guide from side of front
seat base.
2.Remove seat belt lower anchorage bolt.
3.Remove plastic cap from upper belt guide bolt.
4.Remove bolt securing belt guide to 'B' post.
5.Move rear carpet aside and remove bolt
securing inertia reel to base of 'B' post.
6.Remove seat buckle stalk anchorage bolt at
inside rear of front seat.
Refit
NOTE: Tighten all seat belt anchorage
bolts to
32 Nm (24 lbf/ft).
7.Fit seat buckle stalk to mounting at rear of front
seat.
8.Position inertia reel to base of 'B' post and
secure with bolt.
9.Reposition carpet.
10.Fit upper guide to 'B' post.
11.Fit plastic cap to guide bolt.
12.Fit seat belt to seat base lower anchorage
bracket.
13.Fit plastic seat belt guide to seat base.