1996 LAND ROVER DEFENDER length

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.

CHASSIS AND BODY
3
REPAIR
Refit
7.Remove any trim fasteners held in door panel.
Refit or insert new clips to trim panel.
8.Ensure that anti-vibration pads are in position
and offer-up trim casing to door. Align fasteners
with holes in door and firmly push trim into
position.
9.Fit bezels to locking button and remote control
lever.
10.Fit single screw behind remote control lever.
11.Fit door pull and secure with 2 screws and
finisher caps.
12.Fit window regulator handle and retain with
single screw and finisher.WINDOW REGULATOR - REAR SIDE 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, wind window up to its
fullest extent and support glass with a length of
timber, to prevent it falling when removing
regulator.
4.Remove 4 screws retaining regulator to
mounting panel and withdraw regulator whilst
sliding lifting arm button from lifting channel. To
assist this operation, remove timber and lower
glass.

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
14
REPAIR DOOR GLASS - FRONT DOOR
Service repair no - 76.31.01
Remove
1.Remove mounting panel
See Mounting panel
- front door
.
2.Remove window regulator.
3.Push glass up to top of its travel and support
with a suitable length of timber.
4.Remove 2 self tapping screws securing window
glass runner on latch side of door and single
screw from hinge side.
5.Taking care not to damage paint, prise exterior
waist weather strip from door.
6.Remove timber support and lower glass to
bottom of door.
7.Ease runner from glass at hinge side of door, lift
glass over bottom edge of door and withdraw.

WIPERS AND WASHERS
1
OVERHAUL WIPER MOTOR
Service repair no - 84.15.18.
Dismantle
1.Remove wiper motor from vehicle
See Repair,
Wiper motor and drive rack.
2.Remove wiper motor gearbox cover.
3.Remove circlip and plain washer securing
connecting rod.
4.Withdraw connecting rod.
5.Withdraw flat washer.
6.Remove circlip and washer securing shaft and
gear.
7.Clean any burrs from gear shaft and withdraw
gear.
8.Withdraw dished washer.
9.Add alignment marks to yoke and gearbox for
reassembly.
10.Remove yoke securing bolts.11.Withdraw yoke and armature.
12.Remove brush gear assembly.
13.Remove limit switch.
Inspection and test
14.Check brushes for excessive wear, if they are
worn to 4,8 mm in length, fit a new brush gear
assembly.
15.Using a push type gauge, check that brush
spring pressure is 140 to 200 g when bottom of
brush is level with bottom of slot in brush box. Fit
a new brush gear assembly if springs are not
satisfactory.
16.Test armature for insulation and open- or
short-circuits. Use a 110 V 15 W test lamp. Fit a
new armature if faulty.
17.Examine gear wheel for damage or excessive
wear.
Key to wiper motor components
1.Flexible drive
2.Gearbox cover
3.Connecting-rod retaining washer and circlip
4.Connecting-rod
5.Flat washer
6.Gear shaft retaining washer and circlip
7.Drive gear8.Dished washer
9.Alignment marks - yoke to body
10.Yoke securing bolts
11.Armature and yoke
12.Brush gear assembly
13.Limit switch