1996 LAND ROVER DEFENDER tow

64REAR SUSPENSION
4
REPAIR ANTI-ROLL BAR
Service repair no - 64.35.08
Remove
1.Note for reassembly, position of rubber bushes
on anti-roll bar.
2.Remove 4 nuts, bolts and washers securing both
anti-roll bar bush straps to chassis mounting
brackets.
3.Remove nuts, bolts, washers and rubber bushes
securing anti-roll bar to links.
4.Remove anti-roll bar.Refit
5.Position rubber bushes on anti-roll bar. Fit joint
towards axle.
6.Fit anti-roll bar with two straps. Ensure link arms
point down as shown. Loosely fit, bolts, washers
and new nyloc nuts.
7.Fit bolt, washers and rubber bushes. Fit anti-roll
bar to links and tighten to
68Nm (50 lbf/ft).
8.Tighten nuts securing straps to30Nm (22 lbf/ft).

70BRAKES
4
OVERHAUL Assembling master cylinder
CAUTION: It is important that the following
instructions are carried out precisely,
otherwise damage could be caused to new
seals when inserting plungers into cylinder bore.
Generous amounts of new brake fluid should be
used to lubricate parts during assembly.
NOTE: Thoroughly check that no debris is
lodged in fluid passageways and drillings.
If debris is found, carefully remove,
re-clean cylinder and re-check.
16.Fit new swirl tube to bottom of cylinder bore.
17.Lubricate secondary plunger and cylinder bore.
Offer plunger assembly to cylinder until
recuperation seal is resting centrally in mouth of
bore. Gently introduce plunger with a circular
rocking motion, as illustrated. Ensuring that seal
does not become trapped, ease seal into bore
and slowly push plunger down bore in one
continuous movement.
18.Fit primary plunger assembly using same
method as for secondary plunger, push plunger
down bore.
19.Fit original guide ring to support primary plunger.
20.Coat a new 'O' ring with brake fluid and fit to its
respective groove on outer location surface of
master cylinder.
CAUTION: 'O' ring should not be rolled
down outer location surface of master
cylinder but should be slightly stretched
and eased down cylinder and into its groove. Do
not over stretch seal.21.Fit a new retaining ring on outer surface of
master cylinder ensuring that serrations of ring
are facing mounting flange.
22.Fit two new reservoir seals in their respective
ports.
23.Fit a new vacuum seal to either primary plunger
or to bottom of transfer housing bore, open face
of seal towards primary plunger guide ring.
24.Lubricate vacuum seal with brake fluid, fit
transfer housing to master cylinder, push
housing fully up to cylinder mounting flange. Do
not adjust transfer housing after fitting.
25.Lubricate a new water ingress seal with brake
fluid, slightly stretch seal and ease it down
housing until seal is in correct position between
housing and flange.
26.Roll reservoir into top of master cylinder,
reversing procedure described in instruction 3.
27.Fit master cylinder to servo
See Repair,
Master cylinder
.
28.Reconnect battery, and road test vehicle.

76CHASSIS AND BODY
4
REPAIR
Refit
5.Insert lifting arm button into lifting channel.
6.Position regulator so that fixing holes line-up with
holes in mounting panel.
7.Secure with 4 screws and tighten evenly.
8.Temporarily fit handle and check that glass can
be raised and lowered smoothly without tight
spots.
9.Fit plastic sheet.
10.Fit door trim
See Door trim casing.EXTERIOR HANDLE - REAR SIDE DOOR
Service repair no - 76.58.02
Remove
1.Remove door trim casing
See Door trim casing
.
2.Peel back sufficient of plastic sheet to gain
access to handle mechanism.
3.Disconnect actuating rod from handle operating
lever.
4.Remove 2 screws and withdraw handle and
bezels.
Refit
5.Fit handle to door ensuring that both bezels are
in position - flat faces towards door and secure
with 2 screws.
6.Connect actuating rod to handle operating lever
and secure with spring clip.
7.Re-seal plastic sheet.
8.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
17
REPAIR REAR SEAT CUSHION - 90
Service repair no - 78.10.18/99
Remove
1.Release seat cushion stowage strap.
2.Remove 4 bolts and spring washers and lift seat
cushion from pivot brackets.
3.Remove 4 bolts, plain washers, spring washers
and nuts. Detach both pivot brackets from wheel
arch.
Refit
4.Secure pivot brackets to wheel arch and tighten
bolts to
10 Nm (7 lbf/ft).
5.Position seat cushion in pivot brackets and
secure with 4 bolts and spring washers.
6.Fit stowage strap.REAR SEAT SQUAB - 90
Service repair no - 78.10.58/99
Remove
1.Release seat cushion stowage strap and lower
seat cushion.
2.Slacken 2 bolts securing seat squab brackets to
body side.
3.Remove 2 bolts, plain washers, spring washers
and nuts securing seat squab to wheel arch.
4.Lift seat squab and release brackets from
retaining bolts.
Refit
5.Lower seat squab brackets over retaining bolts,
tighten bolts to
10 Nm (7 lbf/ft).
6.Secure seat squab to wheel arch, tighten bolts to
10 Nm (7 lbf/ft).
7.Raise seat cushion and fit stowage strap.

76CHASSIS AND BODY
20
REPAIR REAR SEAT BELTS - 90/110 STATION WAGON,
INWARD FACING SEATS
Service repair no - 76.73.18
Remove
1.Release belt straps from buckles.
2.Release stowage straps and lower both seat
cushions.
3.Unscrew bolt securing lap strap to body
mounting.
4.Remove lap strap, wavy washer, spacer and
plain washer.
5.Repeat operation for buckle strap.
Refit
6.Secure lap strap and buckle straps to body.
Tighten bolts to
32 Nm (24 lbf/ft).
7.If required, secure seat cushions and belts in
stowed position.REAR SEAT BELTS - 110
Service repair no - 76.73.18
Remove
1.Remove rear inward facing seats
See Rear
seat squab - 90
orSee Rear bench seat.
2.Remove side trim panel
See Side trim panel.
3.Remove bolt securing seat belt inertia reel to 'C'
post.
4.Remove seat belt assembly.
5.Pull seat belt straps between seat cushion and
squab into rear of vehicle.
6.Remove finisher cap and bolt securing seat belt
anchorage to floor.
7.Remove seat belt assembly.

84WIPERS AND WASHERS
2
OVERHAUL Assemble
Use Ragosine Listate Grease to lubricate gear wheel
teeth, armature shaft worm gear, connecting rod and
pin, cable rack and wheelbox gear wheels.
Use Shell Turbo 41 oil sparingly to lubricate bearing
bushes, armature shaft bearing journals, gear wheel
shaft and wheelbox spindles. Thoroughly soak felt
washer in yoke bearing with oil.
18.Fit limit switch.
19.Fit brush gear assembly.
20.Fit armature and yoke to gearbox using
alignment marks, secure with yoke retaining
bolts tightening to
23 Nm (17 lbf/ft).If a
replacement armature is being fitted slacken
thrust screw to provide end-float for fitting yoke.
21.Fit dished washer beneath gear wheel with
concave side towards gear wheel.
22.Fit gear wheel to gearbox.
23.Secure gear wheel shaft with plain washer and
circlip.
24.Fit larger flat washer over crankpin.
25.Fit connecting rod and secure with smaller plain
washer and circlip.
26.Fit gearbox cover and secure with retaining
screws.
27.Connect electrical leads between wiper motor
and limit switch.
28.To adjust armature shaft end-float, hold yoke
vertically with adjuster screw uppermost.
Carefully screw in adjuster until resistance is felt,
then back-off one quarter turn.

INSTRUMENTS
5
REPAIR FUEL GAUGE TANK UNIT - SIDE FUEL TANK
Service repair no - 88.25.31
WARNING: Ensure that fuel handling
precautions given in Section 01 -
Introduction are strictly adhered to when
carrying out the following instructions.
Remove
1.Disconnect battery.
2.Remove RH front seat cushion.
3.Release retaining catch and remove seat base
cover to gain access to fuel tank.
4.Disconnect electrical plug from fuel gauge unit.
5.Release locking ring and withdraw fuel gauge
unit from tank, complete with sealing ring.
Refit
6.Insert gauge unit into tank with float positioned
towards front of tank. Fit new sealing washer, if
necessary.
7.Secure gauge unit with locking ring.
8.Fit electrical plug.
9.Fit seat base cover and seat cushion.
10.Reconnect battery.