1996 LAND ROVER DEFENDER oil

STEERING
5
OVERHAUL
Rack thrust pad and adjuster
43.Examine thrust pad for scores.
44.Examine adjuster for wear in pad seat.
45.Fit new sealing ring to rack adjuster.
Rack and piston
46.Examine for excessive wear on rack teeth.
47.Ensure thrust pad bearing surface is free from
scores and wear.
48.Ensure piston outer diameters are free from
burrs and damage.
49.Examine seal and ring groove for scores and
damage.
50.Fit new ring to piston. Warm nylon seal and fit to
piston.
51.Slide piston assembly into cylinder with rack
tube outwards.
Reassemble
NOTE: When fitting replacement oil seals
lubricate with recommended fluid and
ensure absolute cleanliness.
Sector shaft oil seal
52.Fit oil seal, lip side first.
53.Fit extrusion washer.
54.Fit dust seal, lipped side last.
55.Fit circlip.
Fitting valve and worm assembly
56.Refit original shims and inner bearing cup. Use
Petroleum Jelly to aid assembly.
NOTE: If original shims are not used, fit
shims of 0.76 mm thickness.
57.Fit inner cage and bearings assembly.
58.Fit valve and worm assembly.
59.Fit outer cage and bearings assembly.
60.Fit outer bearing cup.

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
.

FRONT SUSPENSION
1
DESCRIPTION AND OPERATION DESCRIPTION
The front suspension design allows maximum wheel
travel and axle articulation providing good ground
clearance without loss of traction or directional
stability.
Long radius arms are fitted to the front axle and
provide maximum axle articulation which is vital for off
road performance. The radius arms are secured to
fabricated mounting brackets welded to the front axle.
Flexible rubber bushes are used on a stem end joint
to secure the rear of the radius arms to mountings on
the chassis cross member.
A panhard rod, which ensures that the front axle
remains centrally located, is fitted transversely and
also uses ferrule rubber bush mountings at both axle
and chassis locations.Two rubber bearing bushes, with retaining straps,
secure the rear of the anti-roll bar to the chassis
mountings, while bushed links support the front of the
bar to the front axle.
Conventional long travel coil springs and hydraulic
shock absorbers are used to control body movement
in all conditions. The shock absorbers are secured to
fabricated towers which are bolted to the chassis. The
upper and lower fixings use a single location stud with
flexible rubber bushes, support washers and securing
nuts. Retaining plates are used to secure the coil
springs to the fabricated towers and axle mountings.
Rubber bump stops are fitted underneath the chassis,
adjacent to the front road springs, and prevent
possible damage that could occur should there be
excessive axle to chassis movement.
Front suspension
1.Panhard rod
2.Radius arms
3.Coil springs
4.Shock absorber
5.Anti-roll bar

REAR SUSPENSION
1
DESCRIPTION AND OPERATION DESCRIPTION
The rear suspension design locates the rear axle with
two round section steel lower link arms and a forged
'A' frame, upper link assembly. This system allows
maximum axle articulation and wheel travel while
maintaining roll stiffness and directional stability.
The link arm is secured by a single retaining nut to the
chassis mounting, comprising a rubber bushed
bracket, which is retained by three fixings. A ferrule
rubber bush with a single retaining bolt is used to
secure the link arm to its axle mounting.
The upper link assembly is located on the rear
differential housing by a pivot ball-pin assembly. Two
brackets bolted to the chassis crossmember support
both sides of the 'A' frame of the link assembly,
secured by single retaining bolts.A Boge Hydromat self levelling unit can be fitted, as
an option, on 110/130 models to give additional
support when the vehicle is used to carry heavier
loads.
Two rubber bearing bushes, with retaining straps,
secure the rear of the anti-roll bar, if fitted, to the
chassis mountings, while bushed links support the
front of the anti-roll bar to the axle.
Conventional long travel coil springs and hydraulic
shock absorbers are used to control body movement.
The shock absorbers are secured to chassis mounting
brackets and fabricated lower mountings welded to to
the rear axle. Retaining plates are used to secure the
coil springs to the axle mounting while fabricated
brackets, welded to the chassis, are used for the
upper spring location.
Rear axle suspension
1.'A' frame, upper link assembly
2.Lower link
3.Coil springs
4.Shock absorber

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)

BRAKES
1
REPAIR GENERAL BRAKE SERVICE PRACTICE
Brake fluid precautions
WARNING: Do not allow brake fluid to
come into contact with eyes or skin.
CAUTION: Brake fluid can damage
paintwork, if spilled wash off immediately
with plenty of clean water.
CAUTION: Use only correct grade of brake
fluid. If an assembly fluid is required use
ONLY brake fluid. Do NOT use mineral oil,
i.e. engine oil etc.
CAUTION: Thoroughly clean all brake
calipers, pipes and fittings before
commencing work on any part of the brake
system. Failure to do so could cause foreign
matter to enter the system and cause damage to
seals and pistons which will seriously impair the
efficiency of the brake system. To ensure the
brake system efficiency is not impaired the
following warnings must be adhered to :-
·DO NOT use any petroleum based cleaning
fluids or any proprietary fluids containing
petrol.
·DO NOT use brake fluid previously bled from
the system.
·DO NOT flush the brake system with any fluid
other than the recommended brake fluid.
The brake system should be drained and flushed
at the recommended service intervals.
Cover all electrical terminals carefully to make
absolutely certain that no fluid enters the
terminals and plugs.FLUID LEVEL CHECK/TOP UP
WARNING: Clean reservoir body and filler
cap before removing cap. Use only fluid
from a sealed container.
1.Park vehicle on level ground.
2.Check level is between 'MIN' and 'MAX' marks.
3.If level is below 'MIN' mark top up fluid level to
'MAX' mark on reservoir, using correct fluid.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
CAUTION: Do not fill reservoir above
maximum line.

70BRAKES
10
REPAIR FRONT BRAKE CALIPERS
Service repair no - 70.55.05
Service repair no - 70.55.16
Before starting repair refer to general brake service
practice
See General Brake Service Practice.
Remove
1.Remove front road wheels.
2.Expose flexible brake hose by moving coiled
protective covering.
3.Using a recognised hose clamp, clamp hose to
prevent loss of brake fluid.
4.Disconnect rigid brake pipe from flexible hose,
seal exposed ends to prevent ingress of dirt.
5.Remove split pin, retaining pins and springs,
withdraw pads. If refitting pads, identify them for
assembly to original locations.
6.Remove 2 bolts and withdraw caliper from swivel
housing.
WARNING: Do not separate caliper halves
7.Clean outer surfaces of caliper using aerosol
brake cleaner.
8.Using special toolLRT-70-500, clamp pistons in
inboard half of caliper. Gently, keeping fingers
clear, and withCAUTION, apply air pressure to
fluid inlet port to expel pistons. It is unlikely that
pistons will expel at same time, regulate rate
with a suitable piece of wood between
appropriate piston and caliper.
9.Finally remove pistons, identifying them with
their respective bores.
10.Remove wiper seal retainer by inserting a blunt
screwdriver between retainer and seal. Pry
retainer carefully from mouth of bore.
11.Taking care not to damage seal grooves, extract
wiper seal and fluid seal.
12.Clean bores, pistons and seal grooves using
clean brake fluid only. If caliper or pistons are
corroded, or their condition is not perfect, new
parts must be fitted.

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)