1996 LAND ROVER DEFENDER battery

41TRANSFER GEARBOX
4
REPAIR
36.Remove retaining nut, release clamp, and
disconnect speedometer cable from transfer
gearbox.
37.Remove battery earth strap retaining nut, 1 nut
and 4 bolts, securing transfer box to main
gearbox extension case.
38.Remove retaining nut securing earth leads to RH
side of transfer box.
39.Fit three guide studs,LRT-41-009, through
transfer box bolt holes to support it during
removal.
40.Lower hoist and withdraw transfer box from main
gearbox.
41.Remove transfer box.Refit
42.Ensure joint faces of transfer box and main
gearbox are clean and guide studs,LRT-41-009,
are fitted to extension case.
43.Lubricate oil seal in joint face of transfer box.
44.Secure transfer box to adaptor plate on lifting
hoist and raise hoist until transfer box can be
located over guide studs.
45.Remove guide studs, fit battery earth strap, and
secure transfer box to main gearbox extension
case. Tighten fixings to
45 Nm (33 lbf/ft).
46.Fit electrical leads to differential lock switch.
47.Raise hoist and remove wooden block
supporting main gearbox.
48.Secure LH and RH mounting brackets to
gearbox and tighten fixings to
55 Nm (41 lbf/ft).
49.With assistance and using a body jack between
chassis longitudinals, jack chassis sufficiently to
enable fitment of crossmember.
50.Position chassis crossmember and locate over
fixing studs of LH and RH gearbox mounting
rubbers .
51.Align crossmember and secure to chassis with 4
nuts and bolts on each side.
NOTE: Fit battery earth strap retaining clip
to LH top bolt.
52.Remove body jack.
53.Fit retaining nut to LH and RH mounting rubbers.
Tighten to
21 Nm (15 lbf/ft).
54.Remove 4 bolts securing hoist adaptor plate to
transfer box bottom cover.
55.Lower hoist and move aside.
56.Clean threads of the 4 bolts, coat with Loctite
290, and fit to transfer box bottom cover. Tighten
to
25 Nm (18 lbf/ft).
57.Fit earth leads to RH side of transfer box.
58.Connect differential lock control operating rod to
pivot arm.
59.Fit speedometer cable to transfer box.
60.Fit front and rear propeller shafts to transfer box.
Tighten nuts to
47 Nm (33 lbf/ft).
61.Fit intermediate silencer.See MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
silencer - 90; Refit
orSee MANIFOLD AND
EXHAUST SYSTEM, Repair, Intermediate
pipe - 110/130; Refit
.
62.Refill transfer box with recommended oil
See
SECTION 10, Maintenance, Under vehicle
maintenance

TRANSFER GEARBOX
5
REPAIR REV: 05/9963.Feed transmission brake cable through heel
board. Ensure cable grommet is correctly
located.
NOTE: Apply a soap solution to aid fitment
of cable.
64.Lower vehicle ramp.
65.Connect cable clevis to handbrake lever and fit
handbrake gaiter.
66.Connect high/low lever to operating rod.
67.Fit breather pipe banjo union to high/low
cross-shaft housing.
68.Fit centre access panel to seat base. If fitted,
secure EGR and alarm system diagnostic
connector mounting bracket to front of access
panel.
69.If fitted, reconnect multi-plug to EGR control unit
on base of centre seat cushion or cubby box.
70.Fit seat cushion or cubby box
See CHASSIS
AND BODY, Repair, Cubby box
.
71.Reconnect battery.
72.Check operation of handbrake and adjust as
necessary
See MAINTENANCE , Handbrake
cable
.

STEERING
1
REPAIR STEERING COLUMN
Service repair no - 57.40.01
Remove
1.Remove bonnet.
2.Set road wheels and steering wheel in straight
ahead position.
3.Mark relationship of steering column inner shaft
to top universal joint.
NOTE: collapsible shaft can be
disconnected from steering column only, if
required, by removing bolts from top
universal joint and slackening top bolt of lower
universal joint.
4.Remove 2 bolts from top universal joint and
lower bolt of bottom universal joint. Slacken top
bolt of lower universal joint and withdraw shaft.5.Prise centre cap from steering wheel.
6.Remove steering wheel retaining nut and
withdraw wheel from column spline.
7.Disconnect battery.
8.Remove 4 screws securing instrument panel and
pull panel away from facia to enable
speedometer cable to be disconnected.
9.Disconnect multi-plugs, electrical leads and
connections to vehicle alarm system, if fitted.
See ELECTRICAL, Repair, Vehicle
immobilisation and alarm system
.
10.Withdraw panel complete with instruments.
11.Remove 5 screws and 2 self-tapping screws to
remove top half of nacelle.
12.Ease bottom half of nacelle from switch
gaiters/grommets and remove.

STEERING
7
REPAIR POWER STEERING PUMP
Service repair no - 57.20.14
Remove
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
.
1.Disconnect battery.
2.Remove viscous fan unit
See COOLING
SYSTEM, Repair, Viscous coupling and fan
.
3.Restrain steering pump pulley, slacken but do
not remove 3 bolts securing pulley.
4.Remove drive belt
See ELECTRICAL, Repair,
Auxiliary drive belt
.
5.Remove bolts and remove pulley.
6.Position suitable container beneath steering
pump.
7.Slacken retaining clip and disconnect return
hose from steering pump.
8.Disconnect high pressure pipe from steering
pump.
9.Allow steering fluid to drain into container.
CAUTION: Plug all connections to prevent
ingress of dirt.
10.Remove 4 bolts securing steering pump bracket
to engine auxiliary mounting bracket.
11.Remove pump and bracket assembly.
12.Remove 3 bolts and detach mounting bracket
from pump.
Refit
13.Fit mounting bracket to replacement steering
pump. Tighten bolts to
9 Nm (7 lbf/ft).
14.Fit pump and bracket to auxiliary mounting
bracket. Tighten bolts to
35 Nm (26 lbf/ft).
15.Connect high pressure feed pipe to steering
pump and tighten to
20 Nm (15 lbf/ft).
16.Connect return hose to steering pump. Tighten
retaining clip to
3 Nm (2 lbf/ft).
17.Position pulley to steering pump, coat threads of
bolts with Loctite 242; fit but do not fully tighten
bolts.
18.Fit drive belt
See ELECTRICAL, Repair,
Auxiliary drive belt
.
19.Restrain steering pump pulley, tighten bolts to
10
Nm (7lbf/ft).
20.Fit viscous fan unitSee COOLING SYSTEM,
Repair, Viscous coupling and fan
.
21.Bleed power steering system
See Power
steering system - bleed
.
POWER STEERING PUMP DRIVE BELT
Service repair no - 57.20.02
NOTE: For details of drive belt remove and
refit
See ELECTRICAL, Repair, Auxiliary
drive belt
.

STEERING
9
REPAIR REV: 05/99 STEERING COLUMN LOCK
Service repair no - 57.40.28
Remove
1.Disconnect battery.
2.Set road wheels in straight ahead position.
3.Remove steering wheel
See Steering wheel.
4.Remove instrument panel
See INSTRUMENTS,
Repair, Instrument panel
.
5.Remove steering column nacelle
See Steering
column nacelle
.
6.Note position of harness leads on back of starter
switch and disconnect lucars. If fitted, remove
alarm system passive coil from switch
See
ELECTRICAL, Repair, Vehicle immobilisation
and alarm system
.
7.Using a punch or stud extractor remove 2 shear
bolts securing steering lock/starter switch to
column.
8.Remove steering lock and collect 2 washers
between lock and clamp.
Refit
9.Fit steering lock/switch in position and line up
with switch plunger.
10.Secure lock to column with clamp and new shear
bolts. Evenly tighten bolts but do not shear them.
11.Temporarily fit steering wheel and operate lock
and switch mechanism to ensure it functions
correctly.
12.Fully tighten retaining bolts until heads shear.
13.Connect harness leads to rear of starter switch.
If applicable, fit alarm system passive coil
See
ELECTRICAL, Repair, Vehicle immobilisation
and alarm system
.14.Fit steering column nacelle
See Steering
column nacelle
.
15.Fit instrument panel
See INSTRUMENTS,
Repair, Instrument panel
.
16.Fit steering wheel
See Steering wheel.
17.Reconnect battery.

57STEERING
10
REPAIR STEERING COLUMN NACELLE
Service repair no - 57.40.29
Remove
1.Disconnect battery.
2.Remove steering wheel
See Steering wheel.
3.Remove 5 screws and 2 self tapping screws and
lift top half of nacelle from steeering column
switch assembly.
4.Ease bottom half of nacelle from switch
gaiters/grommets. Remove lower nacelle.
Refit
5.Locate top half of nacelle in position and fit to
switch assembly gaiters/grommets.
6.Locate lower half of nacelle and loosely fit
retaining screws.
7.Ensure switch gaiters/grommets are correctly
located and nacelle is aligned with switch
assembly brackets.
8.Fully tighten screws.
9.Fit steering wheel
See Steering wheel.
10.Reconnect battery.DROP ARM
Service repair no - 57.50.14
Remove
1.Park vehicle on level surface and chock rear
wheels.
2.Raise vehicle and locate axle stands or use a
ramp.
3.Disconnect steering damper from drag link
See
Steering damper
.
4.Disconnect drag link ball joint from drop arm
using extractorLRT-57-018.
5.Mark drop arm and steering box for reassembly.
6.Bend back tabs on locking washer, slacken
retaining nut, but do not remove.
7.Fit extractorLRT-57-012and release drop arm
from steering box spline.

70BRAKES
2
REPAIR BRAKE SYSTEM BLEED
Service repair no - 70.25.02
Preparation
WARNING: Before bleeding the brake
system refer to general brake service
practice.
See General Brake Service
Practice
.
·During bleed procedure, brake fluid level must
not be allowed to fall below the MIN level.
·To bleed the hydraulic circuits, four bleed
nipples are provided, one at each caliper.
·There are two methods by which air can be
removed from the braking system:-
1. MANUAL BLEED PROCEDURE.
2. PRESSURE BLEED PROCEDURE.
Pressure bleed procedure
Purpose designed equipment for pressure filling and
bleeding of hydraulic systems may be used on Land
Rover vehicles. The equipment manufacturer's
instructions must be followed and the pressure must
not exceed 4.5 bar, 65 lb/in
2.
Manual bleed procedure
Equipment required
·Clean glass receptacle
·Bleed hose
·Wrench
·Approx 2 litres (3 pints) brake fluid.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
Master cylinder bleed
1.Disconnect battery.
2.Depress brake pedal fully and slowly 5 times.
3.Release the pedal and wait for ten seconds.
4.Air bubbles will rise into the reservoir during
these instructions.
5.Repeat instructions until a firm resistance is felt
at the pedal.
Complete circuit bleed
1.Disconnect battery.
2.Bleed front calipers, driver's side first. Fit bleed
hose to bleed screw.
3.Dip free end of bleed hose into brake fluid in
bleed bottle.
4.Open bleed screw of caliper.
5.Depress brake pedal fully several times until fluid
is clear of air bubbles.
6.Keeping pedal fully depressed, tighten bleed
screw, then release pedal.
7.Repeat procedure on other front caliper followed
by rear calipers.
8.Fit all bleed screw protection caps.
9.Check/top-up fluid level when bleeding is
complete
See Fluid Level Check/Top-Up.

BRAKES
3
REPAIR MASTER CYLINDER
Service repair no - 70.30.08
Before starting repair refer to general brake service
practice
See General Brake Service Practice.
Remove
1.Disconnect battery.
2.Place a container under the master cylinder to
catch escaping brake fluid.
3.Clean area round master cylinder ports.
4.Disconnect pipes from master cylinder ports.
Cover, not plug, the pipe ends to prevent entry of
dirt.
5.Disconnect electrical leads from reservoir cap.
6.Remove two nuts securing master cylinder to
servo and withdraw cylinder.
7.Remove reservoir cap and drain fluid into
suitable container for disposal.
8.The reservoir is a push fit in the master cylinder
and secured by seals. Carefully ease the
reservoir from the master cylinder by rolling it
from the seals. Note that the two seals are
different sizes.
Refit
9.Insert new reservoir seals in the master cylinder
ports and fit reservoir to master cylinder.
10.Ensuring that water ingress seal is in position, fit
master cylinder to servo. Tighten fixings to
26
Nm (19 lbf/ft).
11.Connect brake pipes to master cylinder ports
and tighten to
15 Nm (11 lbf/ft).
12.Fit electrical leads to reservoir cap
13.Fill reservoir with recommended brake fluid.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids
14.Bleed the brake systemSee Brake system
bleed
.
15.Reconnect battery and road test vehicle.