1996 LAND ROVER DEFENDER air suspension

REAR SUSPENSION
1
REPAIR REV: 05/99 REAR ROAD SPRING
Service repair no - 64.20.01.
Remove
1.Loosen rear road wheel retaining nuts.
2.Support chassis on stands and remove wheels.
3.Support rear axle weight with jack.
4.Disconnect shock absorbers at one end.
5.Position coil spring compressor correctly on road
spring.
6.Compress spring evenly to facilitate removal.
7.Lower axle to free road spring from upper seat.
CAUTION: Avoid lowering axle further than
rear brake flexible hose will allow.
8.Remove spring retainer plate.
9.Withdraw road spring.
10.Collect spring seat.
Refit
11.Position spring seat on axle location.
12.Fit road spring into chassis location and, using a
turning motion, fit to spring seat.
13.Fit spring retainer plate. Tighten bolts to
14 Nm
(10 lbf/ft).
14.Secure shock absorber. Tighten fixing to37 Nm
(27 lbf/ft).
15.Fit road wheels, 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)
REAR SHOCK ABSORBER
Service repair no - 64.30.02.
Remove
1.Loosen road wheel retaining nuts.
2.Support chassis on stands. Remove road wheel
and support rear axle weight with jack.
3.Remove fixings and withdraw shock absorber
from axle bracket.
4.Remove upper fixings.
5.Withdraw shock absorber.
6.If required, remove mounting bracket
7.If required, remove mounting rubbers.
Refit
8.Position shock absorber and fit upper fixings.
9.Secure shock absorber with lower fixings to axle
bracket. Tighten upper and lower fixings to
37
Nm (27 lbf/ft).
10.Fit road wheels, 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)

64REAR SUSPENSION
2
REPAIR BUMP STOP
Service repair no - 64.30.15.
Remove
1.Remove fixings.
2.Remove bump stop.
Refit
3.Position bolts in slots in bracket.
4.Fit bump stop, secure with washers and nuts.SUSPENSION LINK - UPPER
Service repair no - 64.35.44.
Remove
1.Support rear of chassis on stands, allow axle to
hang freely.
2.Remove fixings, upper link bracket to frame.
3.Remove fixings, upper links to pivot bracket.
4.Remove upper link, complete with frame bracket.
5.Remove bolt.
6.Separate link from bracket.
Renew bush
7.Press out rubber bushes.
8.Fit bush centrally in housing.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.

REAR SUSPENSION
3
REPAIR Refit
NOTE: Do no fully tighten fixings until all
components are in position.
9.Secure link to frame bracket.
10.Fit upper link to pivot bracket.
11.Fit frame bracket to chassis mounting.
12.Fully tighten fixings to
176 Nm (130 lbf/ft).
SUSPENSION LINK - LOWER
Service repair no - 64.35.02.
Remove
1.Site vehicle on a ramp .
2.Alternatively, support vehicle on stands under
rear axle.
3.Remove lower link rear fixings.
4.Remove mounting bracket fixings at side
member bracket.
5.Remove lower link complete.
6.Remove locknut.
7.Remove mounting bracket from lower link.
Renew bush
8.Press out rubber bushes.
9.Fit bush centrally in housing.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
Refit
10.Fit mounting rubber to lowerlink.
11.Secure mounting rubber to chassis bracket, but
do not fully tighten locknut.
12.Fit lower link to axle mounting and secure fixing
to
176 Nm (130 lbf/ft).
13.Lower vehicle, allow axle to take up static laden
position, and fully tighten link chassis fixing to
176 Nm (130 lbf/ft).

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).

REAR SUSPENSION
5
REPAIR ANTI-ROLL BAR LINKS
Service repair no - 64.35.24.
Remove
1.Remove 2 nuts, bolts, washers and rubber
bushes from links and lower anti-roll bar to clear
links.
2.Remove cotter pin and loosen castellated nut a
few turns.
3.Release link using special tool18G 1063Aas
shown.
4.Remove castellated nut and remove link.
Refit
5.Fit anti-roll bar link arm and castellated nut. Point
link arm down as shown. Tighten fixing to
40 Nm
(30 lbf/ft)
and fit new cotter pin.
6.Align anti-roll bar to links.
7.Fit bolts, washers and rubber bushes using new
self locking nuts and secure anti-roll bar to links.
Tighten to
68Nm (50 lbf/ft).
SELF LEVELLING UNIT
Service repair no - 64.30.09
Remove
WARNING: The levelling unit contains
pressurised gas and MUST NOT be
dismantled. Repair is by replacement of
complete unit only.
1.Raise and support the vehicle under chassis and
use a jack to support weight of the axle.
2.Disconnect upper links at pivot bracket.
3.Ease up levelling unit lower gaiter and unscrew
lower ball joint at push rod using thin jawed
spanners.
4.Release webbing strap from the chassis.
5.Remove 4 nuts securing top bracket to chassis
and withdraw levelling unit complete with
bracket.
Renew levelling unit ball joints
The ball joints for the levelling unit may be dismantled
for cleaning and examination.
6.Unscrew lower ball joint from pivot bracket.
7.Unscrew ball joint from top bracket.
8.Reassemble ball joints, packing with
Dextagrease G.P. or equivalent. Renew joints if
worn.
9.Check condition of gaiters and renew if
necessary.

64REAR SUSPENSION
6
REPAIR Refit
10.Ensure ball pin threads are clean and smear
Loctite grade CVX on ball pin threads.
11.Fit upper ball joint to levelling unit and secure
gaiter.
12.Fit top bracket complete with levelling unit to
chassis and secure with 4 nuts and tighten to
47
Nm (35 lbf/ft).
13.Fit levelling unit to lower ball joint and secure
gaiter.
14.Attach webbing strap to chassis cross member.
15.Fit upper links to the pivot bracket and retain
with 2 bolts and nuts but do not tighten at this
stage.
16.Remove jack in support of axle and support from
under chassis.
17.Allow suspension to settle and then tighten 2
bolts and nuts retaining upper links to pivot
bracket to
176 Nm (130 lbf/ft).