1996 LAND ROVER DEFENDER steering wheel

MAINTENANCE
7
MAINTENANCE RENEW AUXILIARY DRIVE BELT
Renew drive belt.
See ELECTRICAL, Repair,
Auxiliary drive belt
RENEW COMPRESSOR DRIVE BELT
Renew compressor drive belt.
See AIR
CONDITIONING, Repair, Compressor drive belt
CHECK/TOP UP POWER STEERING RESERVOIR
WARNING: DO NOT start engine if fluid
level in reservoir has dropped below
dipstick - severe damage to the power
steering system could result.
NOTE: Check fluid level with engine
switched off and system cold. Ensure that
steering wheel is not turned after stopping
engine.
1.Clean and remove reservoir cap.
2.Wipe distick clean and fully refit cap.
3.Remove cap and check fluid level. Ensure fluid
level is between UPPER mark and end of
dipstick.
4.Top up, if necessary, with recommended fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids
DO NOT fill above
UPPER mark on dipstick.CHECK/TOP UP CLUTCH FLUID RESERVOIR
WARNING: Clutch fluid will damage
painted surfaces; clean up any spillage
immediately and rinse with plenty of water.
If clutch fluid should come into contact with the
skin or eyes, rinse immediately with plenty of
water.
1.Clean and remove reservoir cap.
2.Check fluid level and top up if necessary,
maintaining the level approximately 10 mm (0.39
in) below top of reservoir, using recommended
fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
lubricants and fluids

10MAINTENANCE
12
MAINTENANCEREV: 05/99 LUBRICATE PROPELLER SHAFT UNIVERSAL
AND SLIDING JOINTS
1.Clean all grease nipples on front and rear
propeller shafts.
2.Using a low pressure hand grease gun, apply
recommended grease
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended lubricants and fluids
to grease
nipples at front and rear propeller shaft universal
and sliding joints.
VISUALLY CHECK BRAKE, FUEL, CLUTCH
HOSES/PIPES/UNIONS FOR CHAFING, LEAKS
AND CORROSION
CHECK EXHAUST SYSTEM FOR LEAKS,
SECURITY AND DAMAGE
RENEW CATALYTIC CONVERTERS
See
MANIFOLD AND EXHAUST SYSTEM, Repair,
manifolds and exhaust system
CHECK FOR FLUID LEAKS FROM POWER
STEERING AND SUSPENSION SYSTEMS,
HYDRAULIC PIPES AND UNIONS FOR CHAFING
AND CORROSION
CHECK/TIGHTEN STEERING UNIT AND STEERING
ROD BALL JOINT FIXINGS, CHECK CONDITION
OF BALL JOINTS AND DUST COVERSBall joints are lubricated for life during manufacture
and require no further lubrication unless the rubber
boot has been dislodged or damaged. All joints should
be checked at specified service intervals, but more
frequently if vehicle is used under arduous conditions.
1.Check for wear in joints by moving ball joint up
and down vigorously. If free movement is
apparent, fit a new joint assembly.
See
STEERING, Repair, Drop arm ball See
STEERING, Repair, Track rod and See
STEERING, Repair, Drag link and drag link
ends
CHECK/TIGHTEN FRONT AND REAR AXLE
SUSPENSION LINK FIXINGS, CHECK CONDITION
OF MOUNTING RUBBERS
DRAIN AND CLEAN FUEL SEDIMENTER, IF
FITTED
The fuel sedimenter is located on a chassis side
member on the RH side of vehicle near rear wheel. It
increases the working life of the fuel filter by removing
larger droplets of water and other matter from fuel.
NOTE: On 110/130 models with a twin tank
fuel system, two sedimenters may be
fitted, one on each side of the vehicle
chassis.
1.Slacken drain plug and allow any water to drain
off.

MAINTENANCE
13
MAINTENANCE REV: 05/992.When pure diesel is emitted, retighten drain
plug.
3.Disconnect fuel inlet pipe at sedimenter. Raise
and support pipe above level of fuel tank to
prevent fuel draining from tank.
4.Support sedimenter bowl, unscrew bolt and
remove bowl.
5.Remove sedimenter element.
6.Clean all components in kerosene.
7.Fit new seals.
8.Fit element into sedimenter bowl.
9.Secure bowl to sedimenter head.
10.Fit fuel inlet pipe to sedimenter.
11.Slacken drain plug and when pure diesel is
emitted, retighten plug.
12.If necessary, prime the system.
See FUEL SYSTEM, Adjustment, Priming
the fuel system
CHECK CONDITION OF ENGINE MOUNTING
RUBBERS
CHECK SECURITY OF TOWING BRACKET
FITTINGSCARRY OUT ROAD OR ROLLER TEST
WARNING: Two wheel roller tests MUST
NOT be carried out.
For details of dynamometer testing.
See
INTRODUCTION, Information, Dynamometer
testing
Check the following components:
1.Engine for excessive noise.
2.Clutch for slip, judder or spin/drag.
3.Gear selection/noise - high/low range.
4.Steering for abnormal noise/effort.
5.Steering for free play.
6.All instruments, gauges and warning indicators.
7.Heater and air conditioning systems.
8.Heated rear screen.
9.Shock absorbers - ride irregularities.
10.Foot brake, on emergency stop, pulling to one
side, binding and pedal effort.
11.Handbrake operation.
12.Seat reclining and latching.
13.Fully extend seat belt, check operation of
retraction and latching. Inertia belts lock when
snatched or vehicle on slope.
14.Road wheel balance.
15.Transmissions for vibrations.
16.Body noises, squeaks and rattles.
17.Excessive exhaust smoke.
18.Engine idle speed.
19.Endorse service record.
20.Report any unusual features of vehicle condition
and additional work required.
ENDORSE SERVICE RECORD

FRONT AXLE AND FINAL DRIVE
1
REPAIR REV: 05/99 FRONT AXLE ASSEMBLY
Service repair no - 54.10.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
axle when lowering or repositioning axle.
1.Support chassis front.
2.Remove road wheels.
3.Support axle weight with hydraulic jack.
4.Remove radius arms to chassis frame nuts.
5.Disconnect steering damper from track rod.
Using a extractor remove track rod links from
swivel pin arms.
6.Remove four nuts and bolts securing radius
arms to axle bracket.
7.Remove radius arms.
8.Remove bolts securing brake hose brackets .
Refit bolts to prevent oil leakage.
9.Remove bolts from brake calipers and tie to one
side.
10.Remove nuts and washers securing shock
absorbers to axle.
11.Disconnect drag link from swivel pin housing
arm.
12.Remove two nuts and bolts securing panhard
rod to axle bracket. Lift rod clear of axle.
13.Mark for reassembly drive shaft flanges.
Remove four nuts and bolts, tie propeller shaft to
one side.
14.Release axle ventilation pipe banjo and lower
axle assembly. Remove road springs.
15.Disconnect anti-roll bar link
See FRONT
SUSPENSION, Repair, Anti-roll bar ball
.
16.Remove axle assembly.
Refit
17.Position axle under vehicle, supporting left side
of axle, and fit anti-roll bar links
See FRONT
SUSPENSION, Repair, Anti-roll bar links
.
18.Fit propeller shaft. Tighten bolts to
47 Nm (35
lbf/ft).
19.Fit panhard rod to axle bracket. Tighten bolts to
88 Nm (65 lbf/ft).
20.Fit drag link to swivel pin arm. Tighten fixings to
40 Nm (30 lbf/ft).
21.Fit shock absorbers to axle.
22.Fit brake calipers. Tighten bolts to
82 Nm (60
lbf/ft).
23.Tighten upper swivel pin bolts to78 Nm (58
lbf/ft).
24.Fit radius arms to axle brackets. Tighten bolts to
197 Nm (145 lbf/ft).
25.Fit steering damper to track rod.
26.Fit radius arms to chassis side member. Tighten
fixings to
197 Nm (145 lbf/ft).
27.Tighten track rod end to40 Nm (30 lbf/ft)and fit
new split pin.
28.Remove chassis supports, fit road wheels and
tighten 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)

STEERING
1
DESCRIPTION AND OPERATION DESCRIPTION
The steering system incorporates a compression joint
in the lower shaft and is designed to collapse on
impact. The mis-alignment of the upper steering
column with the steering box and the inclusion of two
universal joints, is also designed to prevent the
column moving toward the driver under frontal impact.
The steering box is located behind the first chassis
cross member and is connected to the road wheel
swivel housing by a drag link and track rod. A
hydraulic damper absorbs shocks in the steering,
caused by road wheel deflections when operating on
rough terrain.Power steering system
The power steering system comprises a hydraulic
pump which is belt driven from the engine and
supplied with fluid from a reservoir that also acts as a
cooler.
The steering box houses a self neutralizing rotary
valve which is part of the worm/valve assy and an
hydraulic piston/rack to assist the mechanical
operation. The rotary valve which is operated by
movement of the steering wheel, directs fluid pressure
to the appropriate side of the hydraulic piston/rack to
provide assistance.
Power steering system
1.Hydraulic pump
2.Fluid reservoir
3.Steering box
4.Upper column5.Universal joints
6.Lower shaft
7.Compression joint
8.Drag link

STEERING
3
DESCRIPTION AND OPERATION Rotary valve operation
Rotary valve at neutral
The rotary valve assembly comprises a worm (1),
valve sleeve (2), input shaft (4) and torsion bar (5).
The valve sleeve is retained inside the worm by a trim
screw (3), and incorporates valve ports in its inner
bore. The input shaft is attached to the steering wheel
via a steering shaft and steering column and
incorporates valve ports in its outer diameter to align
with those in the sleeve.
The torsion bar, which is secured to the worm and
input shaft with pins (6) at each end, holds the valve
ports in neutral alignment when there is no demand
for assistance.No demand for assistance (Valve at neutral)
When there is no demand for assistance the torsion
bar holds the input shaft and sleeve valve ports in
neutral relationship to one another, allowing equal
pump pressure (A) to both sides of the piston/rack (9).
Any excess fluid flow from the pump returns to the
reservoir via (B).

57STEERING
4
DESCRIPTION AND OPERATION Rotary valve misaligned
Demand for assistance (Valve misaligned)
When the steering wheel and input shaft is turned,
steering resistance transmitted to the worm causes
the torsion bar to be twisted and the valve ports to be
misaligned for a right or left turn. The misalignment of
the valve ports directs all fluid pressure A to one side
of the piston only and allows displaced fluid B on the
other side.
When demanding maximum assistance, any
excessive fluid output from the pump due to high
pump speed, will circulate through the regulator valve
located in the pump unit, causing the temperature of
the fluid and the pump to rise rapidly.CAUTION: To avoid excessive fluid
temperatures which could damage the oil
seals, the steering must not be held on full
lock for more than 30 seconds in one minute.
Only when the steering wheel, and the demand for
assistance, is released, will the torsion bar return the
valve to neutral, allowing the fluid to circulate through
the reservoir where it is cooled.
In the unlikely event of mechanical failure of the
torsion bar, a coarse splined connection (7) between
the input shaft and worm, ensures steering control is
maintained sufficient to allow the vehicle to be
recovered.

STEERING
5
DESCRIPTION AND OPERATION Pump and regulator valve operation
The pump which is belt driven from the engine is an
eccentric roller type and also houses the pressure
regulator and flow control valve. The pressure is
controlled by a spring loaded ball valve (3) which is
housed inside the flow control valve piston (4).
No demand for assistance High flow through box -
Low pressure
With no demand for assistance the rotary valve in the
steering box acts as a pressure relief valve, allowing
fluid (A) to flow freely through the steering box and
back to the reservoir and pump inlet (B).
No demand for assistance
1.Reservoir
2.Pump
3.Pressure control ball valve and spring
4.Flow control valve and spring
5.Press fit plug (ball bearing)
6.Restrictor
The ball plug (5) is pressed into the valve (4)
during manufacture and determines the opening
pressure of pressure relief valve (3).No flow, through box - High pressure
When the steering is turned, the rotary valve
effectively stops all fluid flow through the steering box,
thus causing an increase in pressure (A). This
increase in pressure is felt in the flow control valve
spring chamber where, at a pre-determined pressure
the relief valve (3) will open and allow the pressure to
escape. The fall in pressure in the flow control spring
chamber, allows the flow control valve to move to the
right, which in turn allows pump output (A) to escape
directly into the pump inlet (B).
Assistance demanded
As soon as the steering wheel is released after
making a turn, the system reverts to the condition
seen in J6292 and the road wheels are returned to the
straight ahead position by the mechanical steering
geometry.
In the event of any hydraulic failure, steering control,
though heavy, will be maintained through the
mechanical components in the steering box.