1996 LAND ROVER DEFENDER door lock

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stop to enable rod to be withdrawn.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.

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.

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.

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.

76CHASSIS AND BODY
28
REPAIR TAIL DOOR TRIM CASING
Service repair no - 76.34.09
Remove
1.Unscrew 2 bolts and remove grab handle from
rear door.
2.Remove 2 screws and detach wiper motor cover.
3.Remove 7 screws securing trim casing to door.
4.Remove 2 screws and lift wiper motor harness
cover from harness support bracket.
5.Carefully release 8 clips securing trim casing to
door.
6.Remove trim casing and collect door lock cover.
Refit
7.Position door lock cover, fit trim casing and
secure with clips.
8.Fit harness cover and secure with two screws.
9.Secure door panel with retaining screws.
10.Position wiper motor cover and secure with 2
screws.
11.Position grab handle and secure with 2 bolts.TAIL DOOR LOCK
Service repair no - 76.37.16
Remove
1.Remove door casing
See Tail door trim
casing
.
2.Remove screws, washers and nut retainer plate
securing top of lock to door.
3.Remove nuts, washers and stud retainer plate
securing bottom of lock to door.
4.Withdraw lock assembly.
5.Remove door lock gasket.
6.Clean sealant from retainer plates.
7.Insert key into barrel.
8.Depress lock barrel plunger and withdraw barrel
from lock.
Refit
9.Fit new barrel into lock.
10.Apply sealant to lock retainer plates.
11.Fit lock to door with a new gasket.
12.Secure with retainer plates, screws, washers
and nuts.
13.Close door and check for correct latching with
striker. Adjust striker as necessary
See Tail
door striker - adjust
.
14.Fit door casing
See Tail door trim casing.