1996 LAND ROVER DEFENDER suspension

FRONT SUSPENSION
3
REPAIR REV: 05/99 Refit
11.Assemble shock absorber components.
12.Position shock absorber, complete with bracket
and secure with 4 fixings.
13.Secure shock absorber lower fixing.
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 ROAD SPRING
Service repair no - 60.20.11.
Remove
1.Remove front shock absorber
See Front
shock absorber
.
CAUTION: Avoid over stretching brake
hoses. If necessary, loosen hose
connector locknuts to allow hoses to
follow axle.
2.Lower axle sufficient to free road spring.
3.Withdraw road spring.
4.Withdraw shock absorber bracket securing ring.
Refit
5.Fit shock absorber bracket retaining ring. Retain
in position with a nut.
6.Position road spring and raise axle.
7.Remove nut retaining securing ring.
8.Fit front shock absorber
See Front shock
absorber
.

60FRONT SUSPENSION
4
REPAIR BUMP STOP
Service repair no - 60.30.10.
Remove
1.Remove fixings.
2.Remove bump stop.
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray
.
Refit
3.Position bolts in slots in chassis brackets.
4.Fit bump stop, secure with washers and nuts.ANTI-ROLL BAR
Service repair no - 60.10.01
Remove
1.Mark 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 both links
4.Remove anti-roll bar.
Refit
5.Position bushes on anti-roll bar. Ensure split
points towards axle on RH bush and away from
axle on LH bush.
6.Fit anti-roll bar with two straps. To ensure correct
fit angled sides of bar should point down.
Loosely fit the bolts, washers and nyloc nuts.
7.Fit bolt, washers and rubber bushes. Using new
nuts fit anti-roll bar to links and tighten to
68Nm
(50 lbf/ft).
8.Tighten nuts securing straps to30Nm (22lbf/ft).

FRONT SUSPENSION
5
REPAIR ANTI-ROLL BAR LINKS
Service repair no - 60.10.04.
Remove
1.Remove 2 nuts, bolts, washers and rubber
bushes from ball joint links.
2.Remove cotter pin and loosen castellated nut a
few turns.
3.Release link joint using special tool18G 1063A
as shown.
4.Remove castellated nut and link.
Refit
5.Fit link and castellated nut. Ensure ball joint link
arm points up. Tighten nut 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 fixings to
68 Nm (50 lbf/ft).

FRONT SUSPENSION
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Anti-roll bar
- Strap nyloc nuts 30..............................................................................
- Ball link self lock nut 68........................................................................
- Castellated nut 40................................................................................
Drag link to axle 40.........................................................................................
Securing ring for mounting turret 14...............................................................
Radius arm to chassis 176...............................................................................
Panhard rod mounting arm to chassis 88.......................................................
Panhard rod to axle 88....................................................................................
Panhard rod to mounting bracket 88...............................................................
Tie bar to Panhard rod 110..............................................................................
Radius arm to axle 197....................................................................................

REAR SUSPENSION
1
DESCRIPTION AND OPERATION DESCRIPTION
The rear suspension design locates the rear axle with
two round section steel lower link arms and a forged
'A' frame, upper link assembly. This system allows
maximum axle articulation and wheel travel while
maintaining roll stiffness and directional stability.
The link arm is secured by a single retaining nut to the
chassis mounting, comprising a rubber bushed
bracket, which is retained by three fixings. A ferrule
rubber bush with a single retaining bolt is used to
secure the link arm to its axle mounting.
The upper link assembly is located on the rear
differential housing by a pivot ball-pin assembly. Two
brackets bolted to the chassis crossmember support
both sides of the 'A' frame of the link assembly,
secured by single retaining bolts.A Boge Hydromat self levelling unit can be fitted, as
an option, on 110/130 models to give additional
support when the vehicle is used to carry heavier
loads.
Two rubber bearing bushes, with retaining straps,
secure the rear of the anti-roll bar, if fitted, to the
chassis mountings, while bushed links support the
front of the anti-roll bar to the axle.
Conventional long travel coil springs and hydraulic
shock absorbers are used to control body movement.
The shock absorbers are secured to chassis mounting
brackets and fabricated lower mountings welded to to
the rear axle. Retaining plates are used to secure the
coil springs to the axle mounting while fabricated
brackets, welded to the chassis, are used for the
upper spring location.
Rear axle suspension
1.'A' frame, upper link assembly
2.Lower link
3.Coil springs
4.Shock absorber

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).