1999 LAND ROVER DEFENDER lock

CHASSIS AND BODY
25
REPAIR Refit
12.Position panel assembly, fit bolts and nut and
tighten to10 Nm (7lbf.ft).
13.Connect multiplug to motor.
14.Secure harness clips and sleeve.
15.Connect interior handle link to latch and secure
with clip.
16.Connect multiplug to solenoid, locate solenoid to
mounting panel and tighten screws.
17.Fit and secure link.
18.Remove wedges, lower glass and locate to
regulator. Fit bolts and tighten to6 Nm (4 lbf.ft).
19.Raise and lower glass to check operation.
20.Fit plastic sheet.See this Section.
21.Adjust door lock solenoid.See ELECTRICAL,
Adjustment.PANEL - MOUNTING - REAR DOOR - FROM 02MY
Service repair no - 76.11.29
Remove
1.Remove plastic sheet.See this Section.
2.Lower glass and remove 2 bolts securing door
glass to regulator.
3.Release glass from regulator, raise and wedge
in raised position.
ProCarManuals.com

76CHASSIS AND BODY
26
REPAIR
4.Release clip, detach and remove lock solenoid
link.
5.Release clip and disconnect interior handle link
from latch mechanism.
6.Remove clip and disconnect sill button link.
7.Release clips securing harness to panel.
8.Disconnect multiplug from solenoid.
9.Release harness sleeve and withdraw harness
from door.
10.Remove 5 bolts and 1 nut securing panel.
11.Remove panel assembly.
Refit
12.Position door mounting panel assembly, fit bolts
and nut and tighten to10 Nm (7lbf.ft).
13.Connect multiplug to solenoid.
14.Secure harness clips and sleeve.
15.Connect interior handle link to latch and secure
with clip.
16.Connect link to sill button and fit clip.
17.Fit and secure solenoid link.
18.Remove wedges, lower glass and locate to
regulator. Fit bolts and tighten to6 Nm (4 lbf.ft).
19.Raise and lower glass to check operation.
20.Fit plastic sheet.See this Section.
ProCarManuals.com

CHASSIS AND BODY
35
REPAIR LOCK - TAIL DOOR - FROM 02MY
Service repair no - 76.37.16
Remove
1.Remove tail door trim casing.See this Section.
2.Remove 4 nuts securing tail door lock.
3.Partially withdraw lock assembly, carefully
disconnect central door locking rod from fulcrum
arm.
4.Remove lock assembly.
5.Remove door lock gasket.
NOTE: Do not carry out further
dismantling if component is removed for
access only.
6.Insert key in lock, depress lock barrel plunger
and withdraw barrel from lock.Refit
7.Fit new barrel to lock.
8.Fit new door lock gasket.
9.Fit door locking rod to fulcrum, align lock. Fit and
tighten nuts to10 Nm (7 lbf.ft ).
10.Close door and check for correct latching with
striker. Adjust striker if necessary.See
Adjustment.
11.Fit tail door trim casing.See this Section.
ProCarManuals.com

PANEL REPAIRS
21
SEALING AND CORROSION PROTECTION Seam sealer on rear end assembly
CAUTION: Do not block drain holes when applying seam sealer.
ProCarManuals.com

PANEL REPAIRS
3
PROCEDURES
4.Cut away the bulk of the panel as necessary
using an air saw.
NOTE: On certain panel joints MIG welds
and braze should be removed using a
sander where possible, before cutting out
the panel bulk.
5.Separate spot welded joints and remove panel
remnants using hammer, bolster chisel and
pincers.Prepare Old Surfaces
6.Clean all panel joint edges to a bright smooth
finish, using a belt-type sander.
NOTE: Prior to sanding, remove remaining
sealant using a hot air gun to minimise the
risk of toxic fumes caused by generated
heat.
WARNING: Care must be taken to avoid
excessive heat build up which may be
caused by this equipment.
7.Straighten existing joint edges using shaping
block and hammer.
CAUTION: Where significant straightening
is required, heat must be applied to the
area to avoid stretching the Aluminium.
CAUTION: All tools used for working with
Aluminium must be kept separate from
those used on steel.
ProCarManuals.com

84WIPERS AND WASHERS
2
DESCRIPTION AND OPERATION WINDSCREEN WIPERS - FROM 02MY
1.LH wheelbox
2.Cable
3.RH wheelbox
4.Wiper motor
5.Spindle with DIN taper arm attachment
6.Spacer
7.Locknut
8.Seal
9.Locknuts
ProCarManuals.com

WIPERS AND WASHERS
3
DESCRIPTION AND OPERATION Although windscreen wiper functionality remains the same, the mechanical architecture has undergone significant
changes. The body structure has undergone some minor changes to house the revised wiper linkage.
A modified wiper motor is introduced which is balanced to reduce operation noise. The brush plate is fitted with
capacitors to reduce radio interference and a thermal cut-out is introduced to prevent motor burnout. The motor
also contains a new park switch which also reduces operation noise. A common motor is now used on both LHD
and RHD variants.
The motor is repositioned on the bulkhead which allows a straighter drive cable run. The straighter run reduces
load on the cable allowing a stiffer cable to be used. The stiffer cable and the incorporation of a reduced friction
material reduces torsion wind-up of the cable and results in smoother wiper operation and a reduction of blade
over travel.
New, larger wheel boxes are fitted in an inverted position from the previous installation. The bulkhead mounting
holes are larger with flats for positive location of the wheel box spindle. The wheel boxes now feature a 40 tooth
gear ratio in lieu of a 32 tooth gear. This reduces backlash and load and further reduces blade over travel. The
wheel box casings are secured with locknuts.
The wheel box spindles now have a splined DIN taper fitting for the new wiper arms which are secured on the
spindle with an M8 nut. The taper improves arm retention.
A new grease is introduced which improves wiper operation at very low temperatures.
ProCarManuals.com

84WIPERS AND WASHERS
6
REPAIR
6.Identify and remove relay.
Refit
7.Fit relay.
8.Position instrument pack and connect multiplugs.
9.Fit instrument pack to fascia and secure with
screws.
10.Connect battery negative lead.See
ELECTRICAL, Repair.MOTOR - WIPER - TAIL DOOR - FROM 02MY
Service repair no - 84.35.12
Remove
1.Remove spare wheel from tail door.
2.Raise nut cover, remove nut and release wiper
arm.
3.Remove nut and collect washer securing wiper
motor to tail door.
4.Open tail door.
5.Remove tail door trim casing.See CHASSIS
AND BODY, Repair.
6.Remove bolt securing door locking solenoid to
tail door.
7.Pivot both assemblies and withdraw wiper motor
from tail door.
8.Disconnect multiplugs from wiper motor.
9.Remove wiper motor assembly.
ProCarManuals.com