1999 LAND ROVER DEFENDER alignment

CLUTCH
1
REPAIR CLUTCH ASSEMBLY
Service repair no - 33.10.01.01
Remove
1.Remove gearbox assembly.See MANUAL
GEARBOX, Repair.
2.Restrain flywheel.
3.Working in sequence, loosen 6 nuts securing
clutch cover to flywheel.
4.Remove clutch cover and clutch plate.
Refit
5.Clean clutch cover and flywheel mating faces
and spigot bush in end of crankshaft.
6.Position clutch drive plate to flywheel with
’gearbox side’ facing towards gearbox.
7.PositionLRT-12-152alignment tool through
drive plate into spigot bearing in crankshaft.8.Fit clutch cover and locate on dowels.
9.Position clutch cover nuts and tighten in diagonal
sequence to25 Nm (18 lbf.ft).
10.Fit gearbox assembly.See MANUAL
GEARBOX, Repair.
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51REAR AXLE AND FINAL DRIVE
2
OVERHAUL
CAUTION: To prevent permanent damage
to the gear carrier case, it must not be
over-stretched. Each flat on the turnbuckle
is numbered to enable a check to be made on the
amount turned. The maximum stretch permitted is
0,30 mm, equivalent to three flats.
15.Ease off adjuster and remove spreader.
Using axle compressor LRT-51-503
16.Place tool on to differential casing, as illustrated,
with weld seam uppermost. Ensure that plates
rest squarely on differential machined surface
and end bars butt against edges of casing.
17.Tighten adjusting nuts by hand only, until all
slack is taken up.
18.Continue to tighten both nuts alternately with a
spanner, one flat at a time, to a maximum of
three flats.
19.Carefully lever-out differential assembly.
Dismantle differential
20.Add alignment marks between crown wheel and
differential case for reassembly purposes, then
remove fixings and withdraw crown wheel.
21.Note alignment markings on two differential
casings to ensure correct refitting, then remove
fixings.
22.Lift off upper case.
23.Withdraw upper differential wheel and thrust
washer.
24.Lift out cross-shaft and pinions.
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77 - PANEL REPAIRS
CONTENTS
Page
INFORMATION
BODY REPAIRS 1..................................................................................................
ELECTRONIC CONTROL UNITS (ECU’s) 3..........................................................
BODY DIMENSIONS
CHASSIS AND BODY 1..........................................................................................
CHASSIS FRAME ALIGNMENT 2..........................................................................
GAP AND PROFILE INFORMATION 9...................................................................
SEALING AND CORROSION PROTECTION
APPROVED MATERIALS 1....................................................................................
APPLICATION EQUIPMENT 4...............................................................................
CORROSION PROTECTION 8...............................................................................
CAVITY WAX 12.....................................................................................................
SEALANTS AND ADHESIVES 17..........................................................................
WATER LEAKS 28..................................................................................................
PANELS
SERVICEABLE PANELS 1.....................................................................................
PROCEDURES
GENERAL WELDING PRECAUTIONS 1...............................................................
PANEL REPLACEMENT PROCEDURE 2..............................................................
REPAIR PROCEDURES 6......................................................................................
REPAIR
WING LOWER FRONT 1........................................................................................
HEADLAMP MOUNTING PANEL 1........................................................................
WING UPPER - LH 2..............................................................................................
WING UPPER - RH 2..............................................................................................
WHEEL ARCH - FRONT 3......................................................................................
BULKHEAD ASSEMBLY 3......................................................................................
SCREEN APERTURE 4..........................................................................................
SILL - FRONT 5......................................................................................................
’B/C’&’D’POST 5..................................................................................................
CORNER CAPPING 6.............................................................................................
BODY SIDE CAPPING 6.........................................................................................
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PANEL REPAIRS
1
INFORMATION BODY REPAIRS
Body shells are of riveted, bolted and welded
construction and are bolted to the chassis frame.
It is essential that design dimensions and strength are
restored in accident rectification. It is important that
neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body or
chassis repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
either individual panels or panel assemblies. The
repairer will determine the repair method and this
decision will take into account a balance of economics
between labour and material costs and the availability
of repair facilities in both equipment and skills. It may
also involve considerations of vehicles down-time,
replacement vehicle availability and repair turn-around
time.
It is expected that a repairer will select the best and
most economic repair method possible, making use of
the facilities available. The instructions given are
intended to assist a skilled body repairer by expanding
approved procedures for panel replacement with the
objective of restoring the vehicle to a safe running
condition and effecting a repair which is visually
acceptable and which, even to the experienced eye,
does not advertise the fact that it has been damaged.
This does not necessarily mean that the repaired
vehicle will be identical in all respects with original
factory build. Repair facilities cannot always duplicate
methods of construction used during production.
The panel repairs shown in this section are all based
on a 110 Station Wagon. Therefore all illustrations
and text relate only to this model. Although certain
areas of the vehicle, such as the front end, are
relevant to all models.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion and if necessary a
road test of the vehicle is carried out, particularly
where safety related items are concerned.Where major units have been disconnected or
removed, it is necessary to ensure that fluid levels are
checked and topped up when necessary. It is also
necessary to ensure that the repaired vehicle is in a
roadworthy condition in respect of tyre pressures,
lights, washer fluid etc.
Body repairs often involve the removal of mechanical
and electrical units as well as associated wiring.
Where this is necessary use the relevant section in
this manual.
Taking into consideration the differences in body
styles, steering and suspension systems as well as
engine and suspension layouts, the location of the
following components as applicable to a particular
vehicle is critical:
Front suspension upper damper
mountings.
Front suspension or sub frame mountings.
Engine mountings on RH and LH chassis
longitudinals.
Rear suspension upper damper mountings.
Rear suspension mountings or lower
pivots.
Steering rack mountings.
Additional points which can be used to check
alignment and assembly are:
Inner holes in crossmember - side - main
floor.
Holes in valance front assembly.
Body to chassis mounting holes.
Holes in rear floor.
Holes in rear lower panels or extension
rear floor.
Fuel tank mountings.
Apertures for windscreen, backlight, bonnet and doors
can be checked by offering up an undamaged
component as a gauge and also by measuring known
dimensions.See BODY DIMENSIONS section.
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77PANEL REPAIRS
2
INFORMATION Straightening
Whenever possible, chassis structural members
should be cold straightened under tension. Do not
attempt to straighten with a single pull, but rework the
damaged area using a series of pulls, releasing
tension between each stage and using the opportunity
to check alignment.
Body jig
Unless damage is limited to cosmetic panels, all repair
work to body members must be carried out on a body
jig, to ensure that impact damage has not spread into
more remote parts of the body structure. Mounting on
a jig will also ensure that the straightening and panel
replacement procedures do not cause further
distortion. If original dimensions cannot be
satisfactorily restored by these methods, damaged
structural members should be replaced. Damaged
areas should be cut away using a high speed saw,
NOT an oxy-acetylene torch.
As a rule, body dimensions are symmetrical about the
centre line. A good initial check for distortion is
therefore to measure diagonally and to investigate
apparent differences in dimensions.Inspection
Every accident produces individual differences in
damage. Each repair is influenced by the extent of the
damage and by the facilities and equipment available
for its rectification.
Most accident damage can be visually inspected and
the approximate extent of the damage assessed.
Sometimes deformation will extend beyond the area
of direct damage, and the severity of this must be
accurately established so that steps may be taken to
restore critical body components to their original
dimensions.
An initial check of critical dimensions can be carried
out by means of drop checks or (preferably) trammels.
Gauges are available which will check accurately for
body twist. Where repairs necessitate renewal of a
critical body component it is recommended that a
body jig is used.
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77PANEL REPAIRS
2
BODY DIMENSIONS CHASSIS FRAME ALIGNMENT
With the vehicle assembled, a check for chassis
squareness can be made as follows:
1.Place the vehicle on a level floor.
2.Mark measuring points at approximately the
locations shown in LR4412M ensuring that the
marks are exactly opposite on each side of the
chassis frame.3.Hold a plumb line against each of the measuring
points in turn and mark the floor directly beneath
the plumb-bob.
4.Move the vehicle and measure diagonally
between the marks made on the floor, if the
chassis is square the diagonals between the
related measuring points should be within 9,50
mm.
5.Chassis frame dimensional checks can be
made, with the vehicle upper structure removed,
referring to the applicable illustration and
associated key.
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77PANEL REPAIRS
4
BODY DIMENSIONS LAND ROVER 90
CHASSIS ALIGNMENT DIMENSIONS
A - Front Datum
B - Chassis Datum
C - Front axle centre line
D - Rear axle centre line
1.239,0 - 236,5 mm
2.82,0 - 79,5 mm
3.633 mm
4.2420,6 - 2418,6 mm
5.2306,4 - 2305,4 mm
6.981,2 - 978,7 mm
7.182,7 mm
8.41,5 - 37,0 mm
9.252 - 250 mm10.110 mm
11.2360mm - Wheelbase
12.636 - 634 mm
13.488 - 482 mm
14.488 - 482 mm
15.3431,1 - 3426,1 mm
16.588,3 - 586,3 mm
17.2313,8 - 2311,8 mm
18.590,5 mm
19.295,25 mm
20.519,30 - 517,30 mm
21.259,80 - 258,50 mm
22.1242,6 - 1240,6 mm
23.642,5 - 639,5 mm24.750,9 mm
25.439,5 - 436,5 mm
26.136,5 mm
27.299,5 - 295,5 mm
28.103 - 100 mm
29.131,5 - 126,5 mm
30.705,5 - 704,5 mm
31.705,5 - 704,5 mm
32.42,2 - 40,2 mm
33.491 - 486 mm
34.594,2 - 593,4 mm
35.283,0 - 282,2 mm
36.32,25 - 31,25 mm
37.397 - 395 mm
Engine mounting dimensions - section V-V
Section V-V, Tdi and Td5 engine mounting bracket dimensions. The dimensions are applicable to all derivatives.
Tdidimensions:
A = 276.5
B = 553
C = 127.9
D = 317.4
E = 4 degreesTd5dimensions:
A = 273.2
B = 546.5
C = 187.8
D = 374.3
E = 4 degrees
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77PANEL REPAIRS
6
BODY DIMENSIONS LAND ROVER 110
CHASSIS ALIGNMENT DIMENSIONS
A - Front Datum
B - Chassis Datum
C - Front axle centre line
D - Rear axle centre line
1.4148 - 4143 mm
2.4009,5 - 4005 mm
3.978,7 - 981,2 mm
4.22 - 20 mm
5.252 - 250 mm
6.239 - 236,5 mm
7.3023,3 - 3022,3 mm
8.3030,7 - 3028,7 mm
9.155 - 153 mm
10.871,2 - 869,2 mm
11.2794 mm - Wheelbase
12.488 - 482 mm13.488 - 482 mm
14.82 - 79,5 mm
15.750,9 mm
16.750,9 mm
17.440,5 - 435,5 mm
18.440,5 - 435,5 mm
19.299,5 - 295,5 mm
20.500 - 495 mm
21.500 - 495 mm
22.594,2 - 593,4 mm
23.594,2 - 593,4 mm
24.283 - 282,2 mm
25.283 - 282,2 mm
26.1970 - 1968 mm
27.642,9 - 639,5 mm
28.750,9 mm29.290,5 mm
30.295,5 mm
31.299,5 - 295,5 mm
32.103 - 100 mm
33.1177,5 - 1175,5 mm
34.1692,5 - 1689,5 mm
35.2610 - 2606 mm
36.2040,5 - 2037,5 mm
37.1912,5 - 1909,5 mm
38.1359 - 1357 mm
39.1573 - 1571 mm
40.270 - 268 mm
41.665,5 - 663,5 mm
42.440 - 438 mm
43.32,25 - 31,25 mm
Section V-V is through the engine mountings. Dimensional information for the mountings can be found in Land
Rover’90’engine mounting dimensions.
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