1996 LAND ROVER DEFENDER ground

MAINTENANCE
1
MAINTENANCE SERVICE SCHEDULE
The following section describes the items detailed in
the vehicle Service Schedule. Where required
instructions are given for carrying out the service
procedure, or a cross reference is given to the section
in the manual where the procedure may be found.
Service Maintenance Schedules are published
separately to reflect the needs and intervals for each
vehicle variant. Procedures in the Workshop Manual
must be used in conjunction with the Service
Schedule sheets.
Service Maintenance Schedules are available from:
Land Rover Publications,
Character Mailing,
Heysham Road,
Bootle,
Merseyside, L70 1JL
VEHICLE INTERIOR
CHECK SEATS & BELTS
Check condition and security of seat belts, seat belt
mountings, seat belt buckles and operation of inertia
seat belts.
CHECK OPERATION OF LAMPS
Check operation of all lamps, horns and warning
indicators.
CHECK OPERATION OF WIPERS
Check operation of front/rear wipers and washers and
condition of wiper blades.CHECK OPERATION OF HANDBRAKE
Handbrake check/adjust
1.Chock road wheels.
2.Raise one rear wheel clear of ground and
support securely with axle stand.
3.Release handbrake lever.
4.Underneath vehicle, tighten adjuster bolt
clockwise to
25 Nm (18 lbf/ft)to fully lock brake
drum.
5.Slacken adjusting bolt by 1.5 turns to give brake
shoes running clearance. Check that the drum is
free to rotate.
6.Adjust handbrake cable locknuts to give pawl
two notches free movement on the rachet before
being fully operational on third notch of rachet.
NOTE: Cable adjustment must ONLY be
used for initial setting and to compensate
for cable stretch. It MUST NOT be used to
take up brake shoe wear, which MUST be adjusted
at brake drum.
7.Operate handbrake to settle brake shoes.
Recheck handbrake is fully operational on third
notch of rachet pawl. Readjust if necessary.
8.Remove axle stand and wheel chocks.

STEERING
11
FAULT DIAGNOSIS STIFF STEERING CHECKLIST
NOTE: Having completed visual checks
and steering assessment and confirmed
that vehicle steering load is incorrect carry
out the following procedure in order shown.
Steering wheel 'torque to turn' loads
1.Raise vehicle so both front wheels free.
2.With engine off, centralise steering wheel, and
remove steering wheel decal. Using torque
wrench on column nut, check torque required to
turn the steering wheel one turn in each
direction.
3.Record readings obtained in each direction.
Reading should be
4.40 Nm (3.5 lbf/ft).
NOTE: If figures are in excess of that
specified carry out steering box tie bar
reset below. If figures are as specified
See
Visual Check and Basic Adjustments
.
Steering box tie bar reset
1.Loosen the tie bar fixings one complete turn.
2.Drive vehicle carefully a short distance (within
the dealership) applying full lock in both
directions in order to settle steering components.
Drive vehicle over speed bumps and include
harsh braking if possible.
WARNING: Do not drive on public
highway.
3.Near end of operation 2. ensure vehicle is driven
in a straight line on level ground and halted.
4.Tighten panhard rod mounting arm nut to
110
Nm (81 lbf/ft).
5.Tighten the 2 fixings, tie bar to steering box, to
81 Nm (60 lbf/ft).
6.Recheck steering wheel torque to turn. If torque
reading is still greater than specified, carry out
steering shaft universal joint lubrication.Lower steering shaft universal joint lubrication
1.Check lower steering shaft is correctly phased
See Repair, Lower Steering Shaft and
Universal Joints
.
2.Lubricate universal joints with an anti-seizure
type penetrating spray. Work the joints to ensure
full penetration of the spray by driving vehicle
and steering from lock to lock.
3.If steering stiffness still persists carry out swivel
pin preload setting.
Swivel pin preload setting
1.The swivel pin preload setting must be checked
and set
See FRONT AXLE AND FINAL DRIVE,
Overhaul, Front Stub Axle, Constant Velocity
Joint and Swivel Pin Housing
.
Note that a pull load of 1.16 - 1.46 kg is required
after the axle shaft and swivel housing seal have
been removed.
Steering box adjustment
1.Check steering box adjustment
See
Adjustment, Power Steering Box
.
Steering damper check
1.Check condition of steering damper
See
Steering Damper
.

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
3
ADJUSTMENT FRONT WHEEL ALIGNMENT
Service repair no - 57.65.01
Checking Toe-out dimensions
NOTE: Recognised front wheel alignment
and tracking equipment should be used
for this operation. Only the use of basic
equipment is described below. No Adjustment is
provided for castor, camber or swivel pin
inclinations.
1.Set vehicle on level ground with road wheels
positioned straight ahead.
2.Push vehicle back and forwards to settle linkage.
3.Set up the equipment to manufacturers
instructions and check alignment as advised by
equipment supplier.
4.Position trammel probes on inner face of wheel,
not the rims, if the latter are damaged.
5.Measure toe-out at horizontal centre-line of
wheels.
6.Check tightness of clamp bolt fixings. Tighten to
14 Nm (10lbf/ft).
Adjust
7.Slacken clamps at both ends of track rod.
8.Rotate track rod to increase or decrease its
effective length until correct toe-out is obtained
See GENERAL SPECIFICATION DATA,
Information, Steering
.
9.Push vehicle rearwards turning steering wheel
from side to side to settle ball joints. With road
wheels set in straight ahead position, push
vehicle forward a short distance.
10.Recheck track and adjust if necessary.
11.When alignment is correct, tap ball joints in
direction of arrows to maximum of travel, to
ensure full unrestricted movement of track rod.
12.Tighten clamp bolts to
14 Nm (10 lbf/ft).
POWER STEERING PUMP DRIVE BELT
Service repair no - 57.20.01
Adjust
NOTE: For details of drive belt adjust
procedure.
See ELECTRICAL, Repair,
Auxiliary Drive Belt

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
12
REPAIR STEERING DAMPER
Service repair no - 57.55.21
Remove
1.Park vehicle on level ground and chock rear
wheels.
2.Raise vehicle and locate axle stands or use a
ramp.
3.Remove bolt securing steering damper to drag
link bracket.
4.Remove retaining nuts, washers and rubber
bush securing damper to chassis mounting.
5.Withdraw damper.
6.Check rubber bushes and washers, renew if
necessary.Refit
7.Ensuring rubber bushes and washers are
correctly positioned, fit steering damper to
chassis mounting.
8.Fit damper to drag link bracket.
9.Remove axle stands or vehicle from ramp.

STEERING
13
REPAIR REV: 05/99 TRACK ROD AND LINKAGE
Service repair no - 57.55.09
Remove
1.Park vehicle on level ground and chock rear
wheels.
2.Raise vehicle and locate axle stands or use a
ramp.
3.Centralise steering
See Adjustment,
Centralise steering box
.
4.Unscrew 2 bolts and remove track rod protection
bracket from axle differential housing.
5.Remove split pin and castellated nut securing
track rod to swivel housing arms.
6.Disconnect track rod ball joints using
LRT-57-018.
7.Remove track rod.
8.Slacken clamp bolts.
9.Unscrew ball joints.

STEERING
15
REPAIR REV: 05/99 DRAG LINK AND DRAG LINK ENDS
Service repair no - 57.55.17
Remove
1.Park vehicle on level ground and chock rear
wheels.
2.Set road wheels in straight ahead position.
3.Raise vehicle and fit axle stands or use a ramp.4.Remove front road wheel.
5.Disconnect steering damper at drag link bracket.
6.Remove split pin and castellated nut securing
drag link ball joint to swivel housing arm.
7.Disconnect drag link ball joints using
LRT-57-018.
8.Remove drag link.
9.Slacken clamp bolts.
10.Unscrew ball joints and remove from drag link.
11.Clean internal threads of drag link.
12.Fit new ends to drag link and loosely fit clamp
bolts.
13.Set ball joints to drag link measurement to 28,5
mm.
14.Adjust ball pin centres to nominal length of 924
mm, this length is adjusted during refit.