1999 LAND ROVER DEFENDER air suspension

REAR AXLE AND FINAL DRIVE
13
OVERHAUL REAR STUB AXLE - 110/130
Service repair no - 64.15.22
STUB AXLE COMPONENTS
1.Rear axle shaft
2.Stub axle to axle casing bolt
3.Mud shield
4.Stub axle
5.Stub axle joint washer
6.Axle caseOverhaul
1.Remove hub assemblySee REAR
SUSPENSION, Repair. Rear hub bearing.
2.Remove 6 bolts from stub axle to axle casing.
3.Remove mud shield.
4.Remove stub axle and joint washer.
5.Remove rear axle shaft from axle casing.
Renew rear stub axle oil seal
6.Remove and discard oil seal. Lubricate seal and
lip EP90 oil. Using special toolLRT-51-004
(LST138) fit new seal lip side trailing so that seal
is flush with rear face of stub axle.
Refit
7.Fit new joint washer, stub axle and mud shield.
Tighten bolts to65 Nm (48 lbf/ft).
8.Fit rear axle shaft, avoid damaging stub axle
seal.
9.Refit hub assemblySee REAR SUSPENSION,
Repair. Rear hub bearing.
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FRONT AXLE AND FINAL DRIVE
1
REPAIR FRONT AXLE ASSEMBLY
Service repair no - 54.10.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
axle when lowering or repositioning axle.
1.Support chassis front.
2.Remove road wheels.
3.Support axle weight with hydraulic jack.
4.Remove radius arms to chassis frame nuts.
5.Disconnect steering damper from track rod.
Using a extractor remove track rod links from
swivel pin arms.
6.Remove four nuts and bolts securing radius
arms to axle bracket.
7.Remove radius arms.
8.Remove bolts securing brake hose brackets .
Refit bolts to prevent oil leakage.
9.Remove bolts from brake calipers and tie to one
side.
10.Remove nuts and washers securing shock
absorbers to axle.
11.Disconnect drag link from swivel pin housing
arm.
12.Remove two nuts and bolts securing panhard
rod to axle bracket. Lift rod clear of axle.
13.Mark for reassembly drive shaft flanges.
Remove four nuts and bolts, tie propeller shaft to
one side.
14.Release axle ventilation pipe banjo and lower
axle assembly. Remove road springs.
15.Disconnect anti-roll bar linkSee FRONT
SUSPENSION, Repair. Anti-roll bar ball.
16.Remove axle assembly.
Refit
17.Position axle under vehicle, supporting left side
of axle, and fit anti-roll bar linksSee FRONT
SUSPENSION, Repair. Anti-roll bar links.
18.Fit propeller shaft. Tighten bolts to47 Nm (35
lbf/ft).
19.Fit panhard rod to axle bracket. Tighten bolts to
88 Nm (65 lbf/ft).
20.Fit drag link to swivel pin arm. Tighten fixings to
40 Nm (30 lbf/ft).
21.Fit shock absorbers to axle.
22.Fit brake calipers. Tighten bolts to82 Nm (60
lbf/ft).
23.Tighten upper swivel pin bolts to78 Nm (58
lbf/ft).
24.Fit radius arms to axle brackets. Tighten bolts to
197 Nm (145 lbf/ft).
25.Fit steering damper to track rod.
26.Fit radius arms to chassis side member. Tighten
fixings to197 Nm (145 lbf/ft).
27.Tighten track rod end to40 Nm (30 lbf/ft)and fit
new split pin.
28.Remove chassis supports, fit road wheels and
tighten 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)
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FRONT AXLE AND FINAL DRIVE
1
OVERHAUL FRONT DIFFERENTIAL
Service repair no - 54.10.07.
Overhaul
NOTE: The front axle differential, for all
models, is the same as that fitted to the 90
rear axle and can only be serviced as a
complete assemblySee REAR AXLE AND FINAL
DRIVE, Repair. Differential assembly - 90.FRONT HUB
Service repair no - 60.25.14.
Overhaul
1.Remove hub assemblySee FRONT
SUSPENSION, Repair. Front hub bearings.
2.Remove outer bearing.
3.Mark, for reassembly, relationship between hub
and brake disc, if original hub is to be refitted.
4.Remove 5 bolts and separate hub from brake
disc.
5.Drift out grease seal and inner bearing from hub
and discard seal.
6.Drift out inner and outer bearing tracks.
7.Clean hub and drift in inner and outer bearing
tracks.
8.Pack hub inner bearing with recommended
grease and fit to hub.
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54FRONT AXLE AND FINAL DRIVE
2
OVERHAUL
9.With lip side leading fit new seal to hub using
special toolLST 137seal replacer and drift18G
134. Drive in seal flush with rear face of hub.
Apply grease between seal lips.
10.Fit brake disc to hub, lining up to marks made
during dismantling. Applying Loctite 270, fit
retaining bolts. Tighten to73 Nm (54 lbf/ft).
11.Grease and fit outer bearing to hub.
12.Fit hub assemblySee FRONT SUSPENSION,
Repair. Front hub bearings.
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FRONT AXLE AND FINAL DRIVE
3
OVERHAUL FRONT STUB AXLE, CONSTANT VELOCITY JOINT
AND SWIVEL PIN HOUSING
Service repair no - 60.15.43.
Remove stub axle, axle shaft and constant
velocity joint.
1.Remove front hub assemblySee FRONT
SUSPENSION, Repair. Front hub bearings.
2.Drain swivel pin housing and refit plug.
NOTE: On later vehicles the swivel pin
housing is filled with grease for life, the
level and drain plugs being deleted.
3.Remove 6 bolts retaining stub axle to swivel
housing.
4.Remove mud shield.
5.Remove stub axle and joint washer.
6.Wthdraw axle shaft and constant velocity joint
from axle casing.
Remove constant velocity joint from axle shaft
7.Hold axle shaft firmly in a soft jawed vice.
8.Using a soft mallet drive constant velocity joint
from shaft.
9.Remove circlip and collar from axle shaft.
Constant velocity joint
10.Mark positions of constant velocity joint, inner
and outer race and cage for reassembly.
11.Swivel cage and inner race to remove balls.
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54FRONT AXLE AND FINAL DRIVE
6
OVERHAUL 38.Place retaining plate, joint washer and oil seal
over axle flange ready for assembly.
39.Fit swivel bearing housing to axle flange with 7
bolts. Tighten to73 Nm (54 lbf/ft).
40.Grease and fit upper and lower swivel pin taper
roller bearings.
41.Position swivel pin housing over swivel bearing
housing.
42.Coat joint washer both sides with sealing
compound and position on lower swivel pin.
43.Loosely fit brake shield bracket plus lower swivel
pin with lug outboard to swivel pin housing.
44.Loosely fit top swivel pin plus existing shims and
brake hose bracket to swivel pin housing.
45.Apply Loctite 270 or equivalent to lower swivel
pin bolts.25 Nm (18 lbf/ft),bend over lock tabs.
46.Tighten top swivel pin bolts to65 Nm (48 lbf/ft).
Check and adjust preload on bearings
NOTE: Swivel housing oil seal and axle
should not be fitted.
47.Attach a spring balance to track rod ball joint
bore and pull balance to determine effort
required to turn swivel pin housing.
Resistance, once initial inertia has been
overcome, should be1.16 to 1.46 kg.Adjust by
removing or adding shims to top swivel pin.
48.When setting is correct remove top swivel bolts,
apply Loctite 270 or equivalent. Refit bolts and
tighten to65 Nm (48 lbf/ft),and bend over lock
tabs.
49.Apply recommended grease between lips of
swivel oil seal.50.Fit oil seal, joint washer and retaining plate with
7 bolts and spring washers. Tighten to11 Nm (8
lbf/ft).
51.Fit tie rod and drag link and secure with new
cotter pins. Tighten fixing to40 Nm (30 lbf/ft).
52.Fit brake disc shield.
53.Loosely fit lock stop bolt and nut.
54.Apply a recommended grease between lips of
swivel housing oil seal.
55.Secure oil seal with retaining plate and securing
bolts. Tighten to11 Nm (8 lbf/ft).
56.Fit track-rod and drag link and secure with new
cotter pins.
57.Loosely fit lock stop bolt for later adjustment.
58.Fit brake disc shield.
Fit driveshaft and stub axle
59.Insert axle shaft, and when differential splines
are engaged, push assembly in fully.
CAUTION: Take care not to damage axle
shaft oil seals.
60.Place a new joint washer in position on swivelpin
housing to stub axle mating face. Coat threads
of stub axle bolts with Loctite 270.
61.Fit stub axle with flat at 12 O’clock position.
CAUTION: Ensure that constant velocity
joint bearing journal is butted against
thrust ring on stub axle before stub axle is
secured.
62.Place mud shield in position and secure stub
axle to swivel pin housing with 6 bolts and
tighten evenly to65 Nm (48 lbf/ft).
63.Fit brake jump hoses to brake jump hose
bracket.
64.Fit complete front hub assemblySee FRONT
SUSPENSION, Repair. Front hub bearings.
65.Check swivel pin housing oil drain plug is fitted.
66.Fill swivel assembly to correct level, with new oil
See MAINTENANCE , Under vehicle
maintenance.
NOTE: On later vehicles fill swivel pin
housing with 0.33 Litres of Molytex EP 00
grease.
67.Set steering lock stop boltsSee STEERING,
Adjustment. Steering lock stops.
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60 - FRONT SUSPENSION
CONTENTS
Page
DESCRIPTION AND OPERATION
FRONT SUSPENSION - FROM 02MY 1................................................................
REPAIR
PANHARD ROD - FROM 02MY 1...........................................................................
BEARINGS - FRONT HUB 1...................................................................................
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FRONT SUSPENSION
1
REPAIR PANHARD ROD - FROM 02MY
Service repair no - 60.10.07.
Remove
1.Remove fixings at mounting arm.
2.Remove fixings at axle bracket.
3.Remove panhard rod.
4.Using a suitable length of steel tubing, press out
flexible bushes. Ensure tubing locates on outer
edge of bush and not on rubber inner.
Refit
5.Fit replacement bushes.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
6.Fit panhard rod to axle bracket and mounting
arm. Tighten fixings to230 Nm (170 lbf/ft).BEARINGS - FRONT HUB
Service repair no - 60.25.14
Remove
1.Raise front of vehicle.
WARNING: Support on safety stands.
2.Remove front road wheel.
3.Pull back front brake caliper jump hose shield
and clamp brake hose.
4.Position container collect brake fluid.
5.Loosen brake pipe to jump hose union and
disconnect.
CAUTION: Use 2 spanners when loosening
or tightening unions.
6.Remove 2 bolts securing brake caliper to hub.
7.Remove brake caliper.
CAUTION: Plug the connections.
8.Remove dust cap.
9.Remove circlip and shim(s) from drive shaft.
10.Remove and discard 5 bolts securing driving
member to hub.
11.Remove driving member and discard gasket.
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