power steering LAND ROVER DEFENDER 1996 Owner's Guide

57STEERING
6
REPAIR POWER STEERING SYSTEM - BLEED
Service repair no - 57.15.02
1.Check that fluid level is at maximum level
See
MAINTENANCE , Under bonnet maintenance.
2.Run engine to normal operating temperature.
3.Recheck reservoir fluid level, top up if necessary
NOTE: During operations 4 to 6, maintain
maximum fluid level in reservoir. Do not
increase engine speed or move steering
wheel.
4.With engine at idle speed, slacken bleed screw.
When fluid seeps past bleed screw retighten
screw.
5.Check fluid level.
6.Clean away fluid around bleed screw.
7.Check hose connections, pump and steering box
for fluid leaks by holding steering on full lock in
both directions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute to avoid overheating fluid and
possibly damaging seals.
8.Carry out road test.POWER STEERING FLUID RESERVOIR
Service repair no - 57.15.08
Remove
1.Position drain tin beneath reservoir.
2.Slacken mounting bracket clamp bolt and raise
reservoir to gain access to feed and return hose
retaining clips.
3.Slacken clips, disconnect hoses from reservoir,
allow fluid to drain.
4.Remove reservoir.
CAUTION: Plug connections to prevent
ingress of dirt.
CAUTION: Discard fluid drained from
system. Do not allow fluid to contact
paintwork, if spilled, remove fluid and
clean area with warm water.
Refit
5.Position reservoir, connect feed and return
hoses and tighten clips to
3 Nm (2 lbf/ft).
6.Fit reservoir in clamp, tighten clamp bolt.
7.Fill reservoir between upper mark and end of
dipstick with power steering fluid
See
MAINTENANCE , Under bonnet maintenance
.
8.Bleed power steering system
See Power
steering system - bleed
.

STEERING
7
REPAIR POWER STEERING PUMP
Service repair no - 57.20.14
Remove
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray
.
1.Disconnect battery.
2.Remove viscous fan unit
See COOLING
SYSTEM, Repair, Viscous coupling and fan
.
3.Restrain steering pump pulley, slacken but do
not remove 3 bolts securing pulley.
4.Remove drive belt
See ELECTRICAL, Repair,
Auxiliary drive belt
.
5.Remove bolts and remove pulley.
6.Position suitable container beneath steering
pump.
7.Slacken retaining clip and disconnect return
hose from steering pump.
8.Disconnect high pressure pipe from steering
pump.
9.Allow steering fluid to drain into container.
CAUTION: Plug all connections to prevent
ingress of dirt.
10.Remove 4 bolts securing steering pump bracket
to engine auxiliary mounting bracket.
11.Remove pump and bracket assembly.
12.Remove 3 bolts and detach mounting bracket
from pump.
Refit
13.Fit mounting bracket to replacement steering
pump. Tighten bolts to
9 Nm (7 lbf/ft).
14.Fit pump and bracket to auxiliary mounting
bracket. Tighten bolts to
35 Nm (26 lbf/ft).
15.Connect high pressure feed pipe to steering
pump and tighten to
20 Nm (15 lbf/ft).
16.Connect return hose to steering pump. Tighten
retaining clip to
3 Nm (2 lbf/ft).
17.Position pulley to steering pump, coat threads of
bolts with Loctite 242; fit but do not fully tighten
bolts.
18.Fit drive belt
See ELECTRICAL, Repair,
Auxiliary drive belt
.
19.Restrain steering pump pulley, tighten bolts to
10
Nm (7lbf/ft).
20.Fit viscous fan unitSee COOLING SYSTEM,
Repair, Viscous coupling and fan
.
21.Bleed power steering system
See Power
steering system - bleed
.
POWER STEERING PUMP DRIVE BELT
Service repair no - 57.20.02
NOTE: For details of drive belt remove and
refit
See ELECTRICAL, Repair, Auxiliary
drive belt
.

STEERING
1
OVERHAUL POWER STEERING BOX - ADWEST
Service repair no - 57.10.07
Overhaul
NOTE: Overhaul of steering box should
not be carried out during the warranty
period.
WARNING: Wear safety glasses while
removing and refitting circlips and
retaining ring.
CAUTION: Absolute cleanliness is
essential when overhauling power steering
box.
1.Remove steering box from vehicleSee Repair,
Power Steering Box
. Mark drop arm and
steering box for realignment on assembly.
Remove drop arm using extractorLRT-57-012.
Loosen drop arm securing nut, but do not
remove before using extractor. Remove dirt
excluder from output shaft.
2.Drain oil, remove blanking plugs and bleed
screw. Hold steering box over suitable container,
turn input shaft from lock to lock, until oil is
drained. Refit bleed screw.
3.Rotate retainer ring until one end is 12 mm from
extractor hole. Using a drift through hole in
cylinder, lift retaining ring from groove in cylinder
bore.
4.Remove retainer ring, using a screwdriver.
5.Turn input shaft (left lock on left hand drive, right
lock on right hand drive) until piston pushes out
cover. Turn input shaft fully in opposite direction,
applying pressure to piston.
6.Remove set screw retaining rack pad adjuster.
7.Remove rack adjuster and pad.
8.Remove sector shaft adjuster locknut.
9.Remove four bolts from sector shaft cover.
10.Screw in sector shaft adjuster until cover is
removed.
NOTE: Sealant is applied to hexagon
socket to 'tamperproof' sector shaft
adjuster.
11.Slide out sector shaft.

STEERING
9
OVERHAUL Input shaft oil seal
92.Fit seal, lip side first, into housing. Use seal
saverLRT-57-016and seal installer
LRT-57-026. Note that seal is fitted to a depth of
4.75 - 5.00 mm from face of box.
93.Secure seal with circlip.
94.Smear inner lip of dirt excluder with PTFE
grease. Fit dirt excluder usingLRT-57-027.
When fitted correctly outer shoulder of excluder
is 4.00 - 4.50 mm from face of box, dimension X.
95.Remove drop arm. Smear inner lip of dirt
excluder with PTFE grease and refit, ensuring
outer lip is flush with casing.
96.With input shaft on centre, align assembly marks
on drop arm and steering box. Fit drop arm to
steering box using a new tab washer. Tighten to
176 Nm (130 lbf/ft),bend over tab.
97.Fit steering box
See Repair, Power Steering
Box
.

STEERING
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
Ball joint nuts 40..............................................................................................
Clamp bolt nuts 9...........................................................................................
Steering column bracket nuts 22....................................................................
Steering wheel nut 43.....................................................................................
Tie bar to mounting nut 110.............................................................................
Universal joint pinch bolt 25............................................................................
PAS box
Adjuster locknut 60.................................................................................
Drop arm nut 176....................................................................................
Sector shaft cover to steering box 75.....................................................
Steering box to chassis 81.....................................................................
Steering box fluid pipes 14mm thread 15...............................................
Steering box fluid pipes 16mm thread 20...............................................
Tie bar 81...............................................................................................
PAS pump
High pressure fluid pipe 20.....................................................................
Power steering pump mounting 35.........................................................
Pulley bolts, power steering pump 10....................................................
Hose clamp 3........................................................................................
Front mounting plate bolts 9..................................................................
PAS reservoir
Hose clamp 3........................................................................................
* Torque values below are for all screws and bolts used except for those that are specified otherwise.
METRIC Nm
M5 6......................................................................................................
M6 9......................................................................................................
M8 25.....................................................................................................
M10 45...................................................................................................
M12 90...................................................................................................
M14 105..................................................................................................
M16 180..................................................................................................
UNC / UNF
1/4 9......................................................................................................
5/16 24...................................................................................................
3/8 39.....................................................................................................
7/16 78...................................................................................................
1/2 90.....................................................................................................
5/8 136....................................................................................................

86ELECTRICAL
8
REPAIR ALARM SOUNDER
Service repair no - 86.55.87
Remove
1.Remove LH front seat cushion.
2.Release retaining clip and remove battery
access cover.
3.Slacken battery negative lead clamp bolt.
4.Turn starter switch 'on'.
5.Turn starter switch 'off' and remove key.
6.Disconnect battery negative lead.
NOTE: Operation 6 needs to be carried out
within 15 seconds to avoid activating
battery backed-up alarm sounder, if fitted.
NOTE: If an alarm sounder without battery
back-up is fitted, it is not necessary to
disconnect battery.
7.Remove 2 nuts securing power steering pump
reservoir mounting bracket to front, LH inside
wing.
8.Move steering pump reservoir aside to gain
access to alarm sounder.
9.Disconnect harness multi-plug from rear of alarm
sounder.
10.Unscrew 2 bolts and remove alarm sounder from
inside wing.
Top illustration - alarm sounderwithbattery
back-up.
Lower illustration - alarm sounderwithout
battery back-up.
NOTE: A new battery backed-up alarm
sounder will not operate until charged by
vehicle generator for approximately three
hours.
Refit
11.Secure alarm sounder to inside wing, tightening
bolts to
10 Nm (7 lbf/ft).
12.Reconnect multi-plug to alarm sounder.
13.Secure power steering pump reservoir to inside
wing, tightening nuts to
10 Nm (7 lbf/ft).
14.Reconnect battery negative lead.
15.Fit battery access cover.
16.Fit LH seat cushion.