1996 LAND ROVER DEFENDER Workshop Manual

76CHASSIS AND BODY
24
REPAIR CUBBY BOX - 90/110 STATION WAGON
Service repair no - 76.25.04
Remove
1.Remove radio/cassette player, if fitted.
2.Open cubby box lid and remove 2 caps
concealing fixing bolts.
3.Remove fixing bolts and washers.
4.Remove 2 screws and lift cup holder from cubby
box.
5.Unscrew 2 bolts securing front of cubby box to
floor mounting.
6.Lift cubby box and, if applicable, release
radio/cassette player leads.
7.If fitted, disconnect multi-plug from EGR control
unit, located on base of cubby box.
8.Remove cubby box.
Refit
9.Position cubby box to mounting and, if
applicable, insert radio/ cassette player leads.
10.Secure front of cubby box to floor and fit cup
holder.
11.Open cubby box lid, secure in position, and fit
bolt caps.
12.Fit radio/cassette player, if fitted.REAR GRAB HANDLE - 90/110 STATION WAGON
Service repair no - 76.58.35
Remove
1.Carefully prise top and bottom edges of finisher
caps from grab handle and then hinge outwards
to gain access to fixing screws.
2.Remove 4 fixing screws and detach grab handle
from rear end trim panel.
Refit
3.Position grab handle on rear end trim panel and
secure with 4 fixing screws.
4.Press finisher caps over screws.

CHASSIS AND BODY
25
REPAIR REAR END LINING - 90/110 STATION WAGON
Service repair no - 76.64.12
Remove
1.Remove rear end trim panel
See Rear end
trim panel
.
2.Remove rear grab handles
See Rear grab
handle
.
3.Carefully prise out 6 trim studs securing rear end
lining to mounting brackets.
4.Remove rear end lining.
Refit
5.Position rear end lining on mounting brackets
and secure with 6 trim studs.
6.Fit rear grab handles
See rear grab handle.
7.Fit rear end trim panel
See rear end trim.

76CHASSIS AND BODY
26
REPAIR FRONT HEADLINING - 90 STATION WAGON
Service repair no - 76.64.10
Remove
1.Remove sun roof headlining finisher.
2.Remove sun visors
See Sun visors.
3.Remove interior lamp
See ELECTRICAL,
Repair, Interior lamp
.
4.Remove interior mirror and mounting plate
See
Interior mirror
.
5.Remove 4 retaining screws and detach both 'A'
post trims.
6.Remove caps and unscrew front seat belt fixing
bolts from 'B' posts.7.Carefully prise side trim panel cap fastener from
'B' posts.
8.Carefully prise 2 cap fasteners, from both sides,
securing headlining to body at door aperture.
9.Carefully prise out 5 cap fasteners securing front
and rear headlinings to roof.
10.From both sides, pull side trim panel inwards
enough to release rear corners of front
headlining.
11.Lower headlining and remove from vehicle.NOTE: Take care not to bend the
headlining on removal and refitting.
Refit
12.With assistance, raise headlining to roof.
13.Carefully pull side trim panel inwards, on both
sides, and slide headlining behind trim panel.
14.Position front headlining into recess of rear
headlining and secure both to roof mounting
brackets with 5 cap fasteners.
15.Secure both sides of front headlining to body at
door apertures with cap fasteners.16.Fit side cap fasteners at 'B' posts.
17.Secure seat belts to 'B' posts and tighten bolts to
32 Nm (24 lbf/ft).Fit caps to bolts.
18.Fit 'A' post trims.
19.Fit interior mirror
See Interior mirror.
20.Fit interior lamp
See ELECTRICAL, Repair,
Interior lamp
.
21.Fit sun visors
See Sun visors.
22.Fit sun roof headlining finisher.

CHASSIS AND BODY
27
REPAIR REAR HEADLINING - 90 STATION WAGON
Service repair no - 76.64.11
Remove
1.Remove side trim panels
See Side trim panel.
2.Remove rear end lining
See Rear end lining.
3.Remove rear interior lamp
See ELECTRICAL,
Repair, Interior lamp
.
4.Carefully prise out 5 trim studs securing rear and
front headlining to roof mounting brackets.5.Release front corners of headlining from cant
rail, on both sides.
6.Pull headlining forwards sufficiently to clear rear
end lining mounting brackets.
7.Release rear corners of headlining from cant rail,
on both sides.
8.Lower rear headlining from roof and remove
from vehicle.NOTE: Take care not to bend headlining
on removal and refitting.
Refit
9.With assistance, position rear headlining to roof
and locate rear corners in cant rail.
10.Push headlining rearwards and position over
rear end lining mounting brackets.
11.Locate front corners of headlining in cant rail.12.Position front edge of rear headlining over front
headlining and secure with trim studs.
13.Adjust rear headlining to achieve good fit at all
corners.
14.Fit rear interior lamp
See ELECTRICAL,
Repair, Interior lamp
.
15.Fit rear end lining
See Rear end lining.
16.Fit side trim panels
See Side trim panel.

76CHASSIS AND BODY
28
REPAIR TAIL DOOR TRIM CASING
Service repair no - 76.34.09
Remove
1.Unscrew 2 bolts and remove grab handle from
rear door.
2.Remove 2 screws and detach wiper motor cover.
3.Remove 7 screws securing trim casing to door.
4.Remove 2 screws and lift wiper motor harness
cover from harness support bracket.
5.Carefully release 8 clips securing trim casing to
door.
6.Remove trim casing and collect door lock cover.
Refit
7.Position door lock cover, fit trim casing and
secure with clips.
8.Fit harness cover and secure with two screws.
9.Secure door panel with retaining screws.
10.Position wiper motor cover and secure with 2
screws.
11.Position grab handle and secure with 2 bolts.TAIL DOOR LOCK
Service repair no - 76.37.16
Remove
1.Remove door casing
See Tail door trim
casing
.
2.Remove screws, washers and nut retainer plate
securing top of lock to door.
3.Remove nuts, washers and stud retainer plate
securing bottom of lock to door.
4.Withdraw lock assembly.
5.Remove door lock gasket.
6.Clean sealant from retainer plates.
7.Insert key into barrel.
8.Depress lock barrel plunger and withdraw barrel
from lock.
Refit
9.Fit new barrel into lock.
10.Apply sealant to lock retainer plates.
11.Fit lock to door with a new gasket.
12.Secure with retainer plates, screws, washers
and nuts.
13.Close door and check for correct latching with
striker. Adjust striker as necessary
See Tail
door striker - adjust
.
14.Fit door casing
See Tail door trim casing.

CHASSIS AND BODY
29
REPAIR TAIL DOOR STRIKER - ADJUST
Service repair no - 76.37.25
Adjust
1.Loosen striker securing screws.
2.Adjust striker and retighten screws.
3.Close door and check for correct latching with
door lock.
4.Carry out further adjustment as necessary. If full
adjustment cannot be achieved carry out
following:
5.Remove striker and nut plate.
6.Elongate holes in body metal which is
sandwiched between striker and nut plate.
7.Refit striker and adjust as necessary.

76CHASSIS AND BODY
30
REPAIR SUN ROOF
Service repair no - 76.83.01
Remove
1.Open sun roof fully.
2.Disengage spring lock from operating handle
catch.
3.Holding sun roof at both sides, release hinges
from locating brackets at front of outer frame.4.Remove sun roof.
5.Starting from centre rear, peel headlining finisher
from inner frame.
6.Remove 18 screws securing inner frame to outer
frame and detach inner frame.
7.Lift outer frame from roof.
NOTE: Assistance may be required to
remove the sun roof assembly.
Refit
8.Clean roof area around outer frame seating.
9.Position outer frame on roof.
10.Fit inner frame to headlining and secure to outer
frame with 18 screws but do not fully tighten.
11.Check alignment of inner and outer frames with
roof mounting and headlining, adjust as
necessary, and fully tighten fixing screws to
10
Nm (7 lbf/ft).
12.Starting from centre rear, fit headlining finisher
lip into locating channel of inner frame.
13.Press finisher firmly over inner frame and
continue around complete frame, ensuring
finisher lies flat on headlining.
14.Fit sun roof hinges fully into locating brackets on
outer frame, and lower the glass panel.
15.Engage operating handle catch with spring lock
of outer frame and close sunroof.

CHASSIS AND BODY
31
REPAIR INTERIOR MIRROR
Service repair no - 76.10.51
Remove
1.Prise interior mirror arm from mounting plate.
2.Remove 3 screws and remove mounting plate
from headlining.
Refit
3.Fit mounting plate to headlining.
4.Locate lower lug of mirror arm in mounting plate
aperture.
5.Press mirror arm firmly to engage spring clip in
mounting plate aperture.SUN VISORS
Service repair no - 76.10.47
Remove
1.Raise sun visor.
2.Remove 2 screws and collect sun visor.
Refit
3.Position sun visor and secure with 2 screws.