1996 LAND ROVER DEFENDER power steering

STEERING
1
OVERHAUL POWER STEERING BOX - ADWEST
Service repair no - 57.10.07
Overhaul
NOTE: Overhaul of steering box should
not be carried out during the warranty
period.
WARNING: Wear safety glasses while
removing and refitting circlips and
retaining ring.
CAUTION: Absolute cleanliness is
essential when overhauling power steering
box.
1.Remove steering box from vehicleSee Repair,
Power Steering Box
. Mark drop arm and
steering box for realignment on assembly.
Remove drop arm using extractorLRT-57-012.
Loosen drop arm securing nut, but do not
remove before using extractor. Remove dirt
excluder from output shaft.
2.Drain oil, remove blanking plugs and bleed
screw. Hold steering box over suitable container,
turn input shaft from lock to lock, until oil is
drained. Refit bleed screw.
3.Rotate retainer ring until one end is 12 mm from
extractor hole. Using a drift through hole in
cylinder, lift retaining ring from groove in cylinder
bore.
4.Remove retainer ring, using a screwdriver.
5.Turn input shaft (left lock on left hand drive, right
lock on right hand drive) until piston pushes out
cover. Turn input shaft fully in opposite direction,
applying pressure to piston.
6.Remove set screw retaining rack pad adjuster.
7.Remove rack adjuster and pad.
8.Remove sector shaft adjuster locknut.
9.Remove four bolts from sector shaft cover.
10.Screw in sector shaft adjuster until cover is
removed.
NOTE: Sealant is applied to hexagon
socket to 'tamperproof' sector shaft
adjuster.
11.Slide out sector shaft.

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OVERHAUL Input shaft oil seal
92.Fit seal, lip side first, into housing. Use seal
saverLRT-57-016and seal installer
LRT-57-026. Note that seal is fitted to a depth of
4.75 - 5.00 mm from face of box.
93.Secure seal with circlip.
94.Smear inner lip of dirt excluder with PTFE
grease. Fit dirt excluder usingLRT-57-027.
When fitted correctly outer shoulder of excluder
is 4.00 - 4.50 mm from face of box, dimension X.
95.Remove drop arm. Smear inner lip of dirt
excluder with PTFE grease and refit, ensuring
outer lip is flush with casing.
96.With input shaft on centre, align assembly marks
on drop arm and steering box. Fit drop arm to
steering box using a new tab washer. Tighten to
176 Nm (130 lbf/ft),bend over tab.
97.Fit steering box
See Repair, Power Steering
Box
.

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1
SPECIFICATIONS, TORQUE REV: 05/99 TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Ball joint nuts 40..............................................................................................
Clamp bolt nuts 9...........................................................................................
Steering column bracket nuts 22....................................................................
Steering wheel nut 43.....................................................................................
Tie bar to mounting nut 110.............................................................................
Universal joint pinch bolt 25............................................................................
PAS box
Adjuster locknut 60.................................................................................
Drop arm nut 176....................................................................................
Sector shaft cover to steering box 75.....................................................
Steering box to chassis 81.....................................................................
Steering box fluid pipes 14mm thread 15...............................................
Steering box fluid pipes 16mm thread 20...............................................
Tie bar 81...............................................................................................
PAS pump
High pressure fluid pipe 20.....................................................................
Power steering pump mounting 35.........................................................
Pulley bolts, power steering pump 10....................................................
Hose clamp 3........................................................................................
Front mounting plate bolts 9..................................................................
PAS reservoir
Hose clamp 3........................................................................................
* Torque values below are for all screws and bolts used except for those that are specified otherwise.
METRIC Nm
M5 6......................................................................................................
M6 9......................................................................................................
M8 25.....................................................................................................
M10 45...................................................................................................
M12 90...................................................................................................
M14 105..................................................................................................
M16 180..................................................................................................
UNC / UNF
1/4 9......................................................................................................
5/16 24...................................................................................................
3/8 39.....................................................................................................
7/16 78...................................................................................................
1/2 90.....................................................................................................
5/8 136....................................................................................................

86ELECTRICAL
8
REPAIR ALARM SOUNDER
Service repair no - 86.55.87
Remove
1.Remove LH front seat cushion.
2.Release retaining clip and remove battery
access cover.
3.Slacken battery negative lead clamp bolt.
4.Turn starter switch 'on'.
5.Turn starter switch 'off' and remove key.
6.Disconnect battery negative lead.
NOTE: Operation 6 needs to be carried out
within 15 seconds to avoid activating
battery backed-up alarm sounder, if fitted.
NOTE: If an alarm sounder without battery
back-up is fitted, it is not necessary to
disconnect battery.
7.Remove 2 nuts securing power steering pump
reservoir mounting bracket to front, LH inside
wing.
8.Move steering pump reservoir aside to gain
access to alarm sounder.
9.Disconnect harness multi-plug from rear of alarm
sounder.
10.Unscrew 2 bolts and remove alarm sounder from
inside wing.
Top illustration - alarm sounderwithbattery
back-up.
Lower illustration - alarm sounderwithout
battery back-up.
NOTE: A new battery backed-up alarm
sounder will not operate until charged by
vehicle generator for approximately three
hours.
Refit
11.Secure alarm sounder to inside wing, tightening
bolts to
10 Nm (7 lbf/ft).
12.Reconnect multi-plug to alarm sounder.
13.Secure power steering pump reservoir to inside
wing, tightening nuts to
10 Nm (7 lbf/ft).
14.Reconnect battery negative lead.
15.Fit battery access cover.
16.Fit LH seat cushion.