torque LAND ROVER DEFENDER 1996 Owner's Guide

57STEERING
12
FAULT DIAGNOSISREV: 05/99 VISUAL CHECK AND BASIC ADJUSTMENTS
NOTE: It is important that the following
instructions are carried out in the
sequence shown and the results recorded.
1.Road springs - check that road springs are
correctly seated and are to correct specification
for vehicle. For spring specification
See
GENERAL SPECIFICATION DATA,
Information, Road Spring Data
.
2.Ride height - measure trim height from wheel
centre to wheelarch eyebrow. Record results on
data sheet.
3.Check/top up power steering fluid
See Repair,
Power Steering Fluid Reservoir
.
4.Check tension and condition of drive belt
See
ELECTRICAL, Repair, Auxiliary drive belt
.
5.Track rod/drag link - check condition of track rod,
drag link and ball joints
See Repair, Drag Link
and Drag Link Ends
.
If either component is damaged, check operation
of steering damper and steering box for
smoothness. Replace all damaged or worn
components that impair the operation of the
steering system.
6.Suspension bushes - examine all steering and
suspension bushes for signs of wear and
deterioration. Also check all fixings for torque
relaxation. Tighten to correct torque value
See
FRONT SUSPENSION, Specifications, torque,
Torque Values
.
7.Oil leaks - check front and rear axle hubs for
leak and repair as necessary.
8.Brake system - check brake system for leaks,
pipe condition, pad wear/contamination, disc
wear/condition.
9.Hub end float - check movement in the hubs by
rocking the wheels.
10.Check front wheel alignment. Vehicles displaying
a tendency to veer more than considered
allowable, it is permissible to set the front track
to parallel.11.Having completed all the above checks and
adjustments, road test vehicle
See Road Test
Procedure
.
Attempt to reproduce the symptoms established
earlier. If symptoms still exist refer to relevant
Diagnostic Chart.
STEERING LINKAGE INSPECT
NOTE: When inspecting steering linkages
and ball joints for wear the following items
must be checked.
Steering ball joints
1.Check ball joint rubber boots for security, signs
of cracking or deterioration.
2.Check ball joint assemblies for seizure i.e. no
movement on ball joint and associated
assemblies.
3.Check for excessive wear. This will be evident
as extreme movement on track rod and steering
linkages. Renew parts as necessary
See
Repair, Track Rod and Linkage
,See Repair,
Drag Link and Drag Link Ends
.
Steering linkages
1.Check all linkages for wear, deterioration and
damage. Renew parts as necessary
See
Repair, Track Rod and Linkage
,See Repair,
Drag Link and Drag Link Ends
.

STEERING
1
ADJUSTMENT POWER STEERING BOX - ADJUST
Service repair no - 57.35.01
WARNING: Adjustments of steering box
should not be required while in warranty
period. If box is stiff or tight and within
warranty, it must be returned to manufacturer. No
attempt must be made to introduce backlash.
1.Apply park brake brake, chock wheels and Jack
up front of vehicle until wheels are clear of
ground.
2.Support chassis front on axle stands.
3.Disconnect drag link from steering drop arm.
4.Check torque to turn
See Fault diagnosis,
Stiff Steering Checklist
.
5.Centralise steering box
See Centralise
Steering Box
.
NOTE: Only check for no backlash when
steering box is in central position.
NOTE: If steering wheel is not straight, it
should be repositioned
See Repair,
Steering Wheel
.
6.Adjustment is obtained by rocking the drop arm
about centre whilst an assistant slowly tightens
the steering box adjuster screw.
7.Tighten locknut when all backlash has been
removed.8.Repeat the check for backlash. If backlash exists
loosen locknut and repeat adjustment
procedure.
9.Turn steering wheel lock to lock and check no
tightness exists.
10.Ensure front wheels are aligned and in straight
ahead position.
11.Adjust drag link 924 mm between ball joint
centres.
12.Connect drag link and tighten to
40 Nm (30
lbf/ft).
13.Lower vehicle to ground level and remove
chocks.
14.Road test vehicle
See Fault diagnosis, Road
Test Procedure
.
Drag link adjust
1.RH drive vehicles - if steering wheel is to right,
drag link is too long. If steering wheel is to left
drag link is too short.
LH drive vehicles - if steering wheel is to right,
drag link is too short. If steering wheel is to left
drag link is too long.
2.Adjust drag link until steering wheel points
straight ahead when vehicle is travelling in a
straight line.
CENTRALISE STEERING BOX
Service repair no - 57.35.05
LH drive vehicle
1.Disconnect drag link from drop arm
See Repair,
Drag link and drag link ends
.
2.Turn steering wheel on full RH lock.
3.Turn steering wheel back exactly two turns.
4.Fit drag link
See Repair, Drag link and drag
link ends
.
RH drive vehicle
1.Repeat operation for LH drive vehicle but turn
steering wheel on full LH lock.

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.

57STEERING
6
OVERHAUL
61.Fit new worm adjuster sealing ring.
62.Loosely screw adjuster into casing.
63.Fit locknut, do not tighten.
64.Turn in worm adjuster until end float is almost
eliminated. Ensure bearing cages are seated
correctly.
65.Measure maximum rolling torque of valve and
worm assembly, using a torque wrench and
spline socketLRT-57-025.
66.Turn in worm adjuster while rotating shaft to
increase figure measured to 0.56 Nm.67.Back off worm adjuster 1/4 turn. Turn in worm
adjuster to increase reading by 0.21 - 0.34 Nm
with locknut tight,
100 Nm (74 lbf/ft).Use worm
adjusting wrenchLRT-57-006and locknut
wrenchLRT-57-028.
Fitting rack and piston
68.Screw slave bolt into piston to aid assembly.
69.Fit piston and rack so piston is 70 mm (2.75 in)
from outer end of bore.
Fitting sector shaft
70.Fit sector shaft using seal saverLRT-57-021.
Align roller with cut out in casing as shown. Push
in sector shaft while rotating input shaft to allow
sector roller to engage worm.
Fitting rack adjuster
71.Fit rack adjuster and thrust pad to engage rack.
Back off half turn on adjuster.
72.Loosely fit new nylon pad and adjuster set screw
assembly.

57STEERING
8
OVERHAUL 84.Refit locknut and tighten.
NOTE: It is important steering box is
centralised before any adjustments are
made.
85.Check maximum rolling torque one and a quarter
turns either side of centre position, using a
torque wrench and spline socketLRT-57-025.
Rotate adjuster screw to obtain across centre
torque of 0.34 Nm plus torque figure at one and
a quarter turns. Tighten adjuster locknut to
60
Nm (44 lbf/ft).
Adjusting rack adjuster.
86.Turn in rack adjuster to increase figure
measured in instruction 85. by 0.23 - 0.34 Nm.
The final figure may be less, but must not
exceed 1.35 Nm.
87.Lock rack adjuster in position with grub screw.
Tighten to
5 Nm (4 lbf/ft).
Torque peak check
With input shaft rotated from lock to lock, rolling
torque figures should be greatest across centre
position and equally disposed about centre position.
The condition depends on value of shimming fitted
between valve and worm assembly inner bearing cup
and casing. The original shim washer value will give
correct torque peak position unless major components
have been replaced.
Procedure
88.With input coupling shaft toward the operator,
turn shaft fully counter-clockwise.
89.Check torque figures obtained from lock to lock
using torque wrench and spline socket
LRT-57-025.
90.Check also for equal engagement either side of
centre.Adjustments
91.Note where greatest figures are recorded
relative to steering position.If greatest figures are
not recorded across centre of travel (steering
straight-ahead), adjust as follows:
If torque peak occursbeforecentre position,addto
shim washer value; if torque peak occursaftercentre
position,subtractfrom shim washer value,
refer to
fitting valve and worm assembly
.
Shim washers are available as follows:
0.03mm, 0.07mm, 0.12mm and 0.24mm.
NOTE: Adjustment of 0.07mm to shim
value will move torque peak area by 1/4
turn on the shaft.
CAUTION: When reshimming valve and
worm, extreme caution must be exercised
to prevent seal damage during
reassembly.

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....................................................................................................

60FRONT SUSPENSION
2
REPAIRREV: 05/99
6.Remove fixings, radius arm to axle.
7.Lower radius arm front end to clear axle and
remove from vehicle.
8.Using suitable length of steel tubing, press out
flexible bushes.
Refit
9.Press in replacement bushes.
CAUTION: When pressing in new bushes
press on outer edge of bush and not
rubber inner.
10.Fit radius arm to axle mounting.
11.Fit track rod at ball joint.
12.Fit radius arm to chassis. Tighten bolts to
176
Nm (130 lbf/ft).
13.Fully tighten radius arm to axle fixings to197 Nm
(145 lbf/ft).
14.Fit road wheel, remove chassis stands and jack.
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)
FRONT SHOCK ABSORBER
Service repair no - 60.30.02.
Remove
1.Loosen road wheel retaining nuts.
2.Support chassis on stands and remove road
wheel.
3.Support axle weight with jack.
4.Remove shock absorber lower fixing and
withdraw cupwasher, rubber bush and seating
washer.
5.Remove four shock absorber bracket fixings.
6.Withdraw shock absorber and bracket assembly.
7.Withdraw lower seating washer, rubber bush and
cupwasher.
8.Remove fixings, shock absorber to mounting
bracket.
9.Withdraw mounting bracket.
10.Lift off top seating washer, rubber bush and
cupwasher.

FRONT SUSPENSION
3
REPAIR REV: 05/99 Refit
11.Assemble shock absorber components.
12.Position shock absorber, complete with bracket
and secure with 4 fixings.
13.Secure shock absorber lower fixing.
14.Fit road wheel, remove chassis stands and jack.
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)
FRONT ROAD SPRING
Service repair no - 60.20.11.
Remove
1.Remove front shock absorber
See Front
shock absorber
.
CAUTION: Avoid over stretching brake
hoses. If necessary, loosen hose
connector locknuts to allow hoses to
follow axle.
2.Lower axle sufficient to free road spring.
3.Withdraw road spring.
4.Withdraw shock absorber bracket securing ring.
Refit
5.Fit shock absorber bracket retaining ring. Retain
in position with a nut.
6.Position road spring and raise axle.
7.Remove nut retaining securing ring.
8.Fit front shock absorber
See Front shock
absorber
.

FRONT SUSPENSION
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Anti-roll bar
- Strap nyloc nuts 30..............................................................................
- Ball link self lock nut 68........................................................................
- Castellated nut 40................................................................................
Drag link to axle 40.........................................................................................
Securing ring for mounting turret 14...............................................................
Radius arm to chassis 176...............................................................................
Panhard rod mounting arm to chassis 88.......................................................
Panhard rod to axle 88....................................................................................
Panhard rod to mounting bracket 88...............................................................
Tie bar to Panhard rod 110..............................................................................
Radius arm to axle 197....................................................................................

REAR SUSPENSION
1
REPAIR REV: 05/99 REAR ROAD SPRING
Service repair no - 64.20.01.
Remove
1.Loosen rear road wheel retaining nuts.
2.Support chassis on stands and remove wheels.
3.Support rear axle weight with jack.
4.Disconnect shock absorbers at one end.
5.Position coil spring compressor correctly on road
spring.
6.Compress spring evenly to facilitate removal.
7.Lower axle to free road spring from upper seat.
CAUTION: Avoid lowering axle further than
rear brake flexible hose will allow.
8.Remove spring retainer plate.
9.Withdraw road spring.
10.Collect spring seat.
Refit
11.Position spring seat on axle location.
12.Fit road spring into chassis location and, using a
turning motion, fit to spring seat.
13.Fit spring retainer plate. Tighten bolts to
14 Nm
(10 lbf/ft).
14.Secure shock absorber. Tighten fixing to37 Nm
(27 lbf/ft).
15.Fit road wheels, remove chassis stands and
jack. 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)
REAR SHOCK ABSORBER
Service repair no - 64.30.02.
Remove
1.Loosen road wheel retaining nuts.
2.Support chassis on stands. Remove road wheel
and support rear axle weight with jack.
3.Remove fixings and withdraw shock absorber
from axle bracket.
4.Remove upper fixings.
5.Withdraw shock absorber.
6.If required, remove mounting bracket
7.If required, remove mounting rubbers.
Refit
8.Position shock absorber and fit upper fixings.
9.Secure shock absorber with lower fixings to axle
bracket. Tighten upper and lower fixings to
37
Nm (27 lbf/ft).
10.Fit road wheels, remove chassis stands and
jack. 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)