Defender (1993+). Manual — part 11

MAINTENANCE

RENEW MAIN AND TRANSFER GEARBOX OILS

DRAIN

AND

RENEW

LT230T

TRANSFER

DRAIN AND REFILL LT77S MAIN GEARBOX

GEARBOX OIL

1.

Drive the vehicle to level ground and place a

1. Drive the vehicle

to

level ground and place a

container under the gearbox

to

catch the old

suitable container under the gearbox

to

catch

oil.

the old oil.

2.

Remove the drain plug and allow the oil to

2.

Remove the gearbox and extension case

drain.

Fit

the plug using a new washer, if

drain plugs and allow the oil to drain

necessary, and tighten to the correct torque.

completely. Wash the extension case filter in

3.

Remove the filler-level plug and inject the

kerosene and refit the plugs using new

approximate quantity

of

the recommended oil

washers, i f necessary, and tighten

to

the

until it begins to run from the plug hole.

Fit

the

correct torque.

level plug and tighten only to the correct

torque, do not overtighten, wipe away any
surplus oil.

3. Remove the oil filler-level plug and inject the

approximate quantity of new oil of the correct
make and grade until it begins to run out of

the filler-level hole. Fit the plug and tighten to
the correct torque. Since the plug has a

Wipe away any surplus oil.

tapered thread it must not

be

overtightened.

10

REISSUED: FEB

1993

ST3084M

ST1070M

MAINTENANCE

RENEW SWIVEL PIN HOUSING OIL

RENEW FRONT AND

REAR

AXLE OIL

1.

Drive the vehicle to level ground and place a

1 .

Drive the vehicle to level ground and place a

container under each swivel housing to catch

container under the axle to be drained.

the used oil.

2.

Using a spanner with a

13

mm

square drive

2.

Remove the drain plug and allow the oil to

remove the drain plug and allow the oil to

drain completely and clean and refit the plugs.

drain completely. Clean and refit the drain

recommended make and grade of oil until oil

3.

Remove the oil filler-level plug and inject new

begins to run from the level hole. Clean and

oil of a recommended make and grade until

it

fit

the level plugs and wipe away any surplus

begins

to

run from the hole. Clean and fit the

Oil.

filler-level plug and wipe away any surplus oil.

3.

Remove the oil filler-level plug and inject the

plug.

LUBRICATE PROPELLER SHAFTS

1.

Clean all the grease nipples on the front and
rear propshaft universal joints, and sliding
portion of the shaft.

2. Charge a low pressure hand grease gun with

grease of a recommended make and grade
and apply to the grease nipple. giving two to
three strokes of the gun only to each nipple
every 40.000 km (24,000 miles) intervals.

RE-ISSUED:

FEB

1993

11

MAINTENANCE

GENERAL MAINTENANCE AND ADJUSTMENT

4 .

Withdraw the pad retaining pins.

5.

Remove the anti-rattle springs and

withdraw

This second part of the maintenance section covers

the friction pads.

adjustments and items of general maintenance as

6.

Clean the exposed surfaces

of

the

pistons

dictated by the 'MAINTENANCE SCHEDULES'

.

with new hydraulic fluid or brake cleaning

However, only maintenance operations that are not

fluid.

included in the OVERHAUL SECTlONS of the

7.

Using piston clamp (18G 672), press each

manual appear in this section.

piston back into its bore, whilst ensuring that

the displaced fluid does not overflow from the

EXAMINE AND RENEW DISC BRAKE FRICTION

reservoir.

PADS

NOTE: Defender 90 has disc type brakes

fitted

to

both front and rear

axles.

Defender 110 is fitted

with disc type brakes at the front and drum type

brakes

at

the rear. Front brakes on both vehicle

types are fitted with four piston calipers and the
rear brakes on Defender 90 are fitted with twin
piston calipers, The procedure for renewing

friction pads is the same for both types although
there

may

be

a variation

in

the type of anti-rattle

spring fitted, see Section 70.

Examine the friction pads for wear, if the friction

material is less than 3 mm thick

or

oil contaminated,

they must be renewed as described

in

the following

instructions. Observe precautions

in

SECTlON

01

concerning asbestos:

CAUTION: Friction pads must

be

changed

in

axle

sets.

1.

Loosen wheel nuts, jack-up the vehicle, lower

onto axle stands. and remove the

wheels.

2.

Clean the exterior

of

me

calipers.

3.

Remove the split pins,

or

spring clips,

from

9.

Insert the new

friction pads.

the pad retaining pins.

8.

Smear the faces of the pistons with disc brake
lubricant, taking care not to allow any to reach
the pad lining material.

10. Place the anti-rattle springs in position.
11. Insert the pad retaining pins and secure with

new split pins.

12. Apply the foot brake pedal several times to

locate the pads.

13. Check the fluid reservoir and top up if

necessary

14

Fit the road wheels and secure with the nuts

Jack up the vehicle to remove the axle stands
and lower m e vehicle to me ground Finally.

tighten the road wheel securing nuts evenly.
to the correct torque.

12

REVISED: OCT

1993

CHANGING THE HYDRAULIC BRAKE FLUID

In the service schedule it

IS

recommended that the

Pipes attached to the breathers on the axles

brake fluid is renewed at 18,000 miles (30.000 km)

terminate inside the engine compartment.

This

allows

intervals or every eighteen months.

If

the following

the axles to breath whilst the vehicle

IS

traversing

procedure is adopted air should not enter the

mud and water. No maintenance is required except

system.

to ensure that the pipes do

not

become blocked,

kinked, or split, or damaged in any other way

to

prevent proper breathing.

AXLE BREATHERS

1

Proceed in the same way and order

as

for

bleeding the system, see

SECTION 70

.

If

a

clear plastic bleed tube is not available,

CHECK STEERING BALL JOINTS

interpose a short length

of

glass tube into the

bleed hose being used

so

that the passage of

the fluid can be seen.

2.

Attach one end

of

the bleed hose to the bleed

nipple of the wheel cylinder nearest to the
master cylinder and immerse the

free

end into

a glass vessel containing a small quantity

of

brake fluid

so

that the end of the tube

is

below the fluid level.

3.

Unscrew the bleed nipple screw about
half-a-turn, enough

to

allow fluid to be

pumped out. Air could be drawn into the
system

if

the screw

is

withdrawn too far.

Ball joints are lubricated for their normal life during
manufacture and require no further lubrication. This
applies only

if

the rubber gaiter has not become

dislodged or damaged. The joints should be checked
at the specified mileage intervals but more frequently
if

the vehicle is

used

under arduous conditions.

MAINTENANCE

1.

Check

for

wear

in

the joints by moving the

ball joint

up

and down vigorously. If free

movement

is

apparent renew the complete

joint assembly.

4

Pump-out most, but not all, of the fluid from
the reservoir by continuously depressing and

releasing the foot pedal. Do not, however,
allow the reservoir to empty completely.

5. Top-up the reservoir with new, unused fluid. of

the correct specification, from a sealed
container. See SECTION 09 .

6. Ensure that the reservoir is kept topped-up

and continue bleeding until the old and
discoloured fluid is dispelled and the new fluid
is seen passing through the clear bleed hose
or glass tube. Continue to bleed for two full

strokes of the pedal and then close the bleed
nipple whilst the pedal is depressed.

7

Repeat the above procedure at the remaining
wheel cylinders in turn.

8. Top-up the reservoir and road test the vehicle.

RE-ISSUED: FEB

1993

‘ 7