1999 LAND ROVER DEFENDER brake

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
5
OVERHAUL Swivel pin housing
22.Remove bolts securing oil seal retaining plate
and joint washer. Release assembly from swivel
pin housing.
NOTE: Removal of oil seal and retaining
plate is achieved when swivel bearing
housing is removed.
23.Remove 2 bolts, retaining lower swivel pin to
housing.
24.Remove brake disc shield bracket.
25.Tap lug to remove lower swivel pin and joint
washer.
26.Remove two bolts retaining brake hose bracket
and top swivel pin.
27.Remove bracket, top swivel pin and shims.
28.Remove swivel pin housing while retrieving
lower and upper bearings.
Swivel bearing housing
29.Remove lower bearing track from swivel bearing
housing.
NOTE: Use upper bearing opening to gain
access to lower bearing track.
30.Remove 7 bolts retaining swivel bearing housing
to axle case.
31.Remove inner oil seal from back of housing.
32.Remove top bearing track from swivel bearing
housing.
NOTE: Use lower bearing opening to gain
access to upper bearing track.
33.If worn, pitted or damaged, renew housing.
34.Fit upper and lower bearing tracks into swivel
bearing housing.
CAUTION: Ensure bearing tracks are fitted
square or damage could occur.
35.With seal lips trailing, fit swivel housing inner oil
seal into rear of housing. Grease seal lips.
Fit swivel pin housing
36.Coat swivel bearing housing to axle casing bolts
with Loctite 270 or equivalent.
37.Coat both sides of joint washer with a sealing
compound. Position swivel bearing housing to
axle mating face.Swivel assembly components
1.Swivel pin housing
2.Top swivel pin and brake hose bracket
3.Upper and lower swivel pin bearings
4.Shim
5.Retaining plate and washer
6.Oil seal
7.Joint washer
8.Swivel bearing housing
9.Joint washer
10.Lower swivel pin
11.Mudshield bracket
12.Swivel housing inner oil seal
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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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57STEERING
2
REPAIR 15.Remove brake servo.See BRAKES, Repair.
16.Release ABS modulator multiplug from side of
brake pedal box.
17.Release mat from underside of fascia to gain
access to brake pedal box mounting bolts.
18.Remove 6 bolts securing brake pedal box to
bulkhead.
19.Disconnect 2 brake pedal switch Lucars.
20.Carefully remove brake pedal box assembly and
collect gasket.
21.Remove bolt securing column upper tie bar to
column.
22.Remove 2 bolts securing upper column to lower
mounting bracket.
23.Remove 2 bolts securing 2 halves of column
upper clamp.
24.Remove 2 bolts securing column upper clamp to
mounting bracket.
25.Remove column upper clamp and collect rubber
packing.
26.Remove 2 bolts securing column upper
mounting bracket to bulkhead.
27.Release upper column from lower column and
manouvre mounting bracket and upper column
assembly from vehicle.
28.Remove mounting bracket from column.
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STEERING
3
REPAIR Refit
NOTE: The steering column is a
non-servicable component and can only
be serviced as a complete assembly.
29.Fit mounting bracket to column and manouvre
assembly into position.
NOTE: Ensure marks on upper and lower
columns are aligned.
30.Loosely fit bolts securing mounting bracket to
bulkhead.
31.Fit upper clamp and rubber packing to column.
32.Loosely fit bolts securing upper clamp to
mounting bracket.
33.Loosely fit bolts securing 2 halves of upper
clamp.
34.Loosely fit bolts securing column lower mounting
bracket.
35.Fit bolt securing upper tie bar to steering column
and tighten to22 Nm (16 lbf.ft).
36.Tighten mounting bracket to bulkhead bolts,
clamp bolts, and lower mounting bolts.
M6 bolts =9 Nm (6 lbf.ft)
M8 bolts =22 Nm (16 lbf.ft)
37.Manouvre brake pedal box assembly and NEW
gasket into position in vehicle.
38.Tighten bolts securing brake pedal box to
bulkhead to25 Nm (18 lbf.ft)
39.Connect brake pedal switch Lucars.
40.Reposition mat to underside of fascia.
41.Secure ABS modulator multiplug to side of brake
pedal box.
42.Fit brake servo.See BRAKES, Repair.
43.Fit ignition switch to steering column, ensuring
inner shaft slot aligns with steering lock plunger.
44.Evenly tighten clamp bolts, but DO NOT shear at
this stage.
45.Temporarily fit steering wheel and check for
correct operation of switch and lock.
46.Remove steering wheel.
47.Fully tighten ignition switch bolts until heads
shear.48.Connect Lucars to rear of ignition switch.
49.Fit passive coil to ignition switch and connect
multiplug.
50.Fit switch assembly to steering column and
tighten clamping screw.
51.Connect column switch multiplugs.
52.Fit instrument pack.See INSTRUMENTS,
Repair.
53.Fit steering column nacelle.See this Section.
54.Fit bolt securing upper column to lower column
universal joint and tighten to25 Nm (18 lbf.ft).
55.Fit air inlet pipe between turbo and inlet air filter
and secure with clips.
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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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