Defender (1993+). Manual — part 101

ELECTRICAL EQUIPMENT

REAR

LAMPS

REVERSE

LIGHT

SWITCH

1.

The rear lamp cluster on the left side

Remove and refit

comprises a rear/stop lamp an amber flasher

lamp and a white reverse lamp.

The reverse light switch is located at the rear of the

On the right side the lamp cluster comprises

gear change housing and is accessible from

only rear/stop lamp and flasher.

underneath the vehicle. Loctite thread locking fluid

rubber using a flat screwdriver to gain access
to

the bulbs.

Removal

The lenses are marked

"Top"

to ensure

correct re-assembly.

1.

Disconnect the battery negative lead.

3.

The lamp units are secured by nuts,

2.

Disconnect the electrical leads from the

accessable under the rear fender. Three nuts
and bolts retain the left lamp cluster and

two

3 . Unscrew the switch from the gear change

nuts and bolts secure the right lamp cluster.

2.

The lenses are easily levered out of the

should be used when fitting this switch.

reverse light, switch.

housing.

Refitting

4.

Coat the switch threads with Loctite 290.

5.

Fit the reverse light switch to the gear change
housing and tighten

to

12

Nm.

6. Connect the electrical leads to the switch.

7.

Connect the battery negative lead.

16

REISSUED: FEB

1993

ELECTRICAL

EQUIPMENT

WARNING LAMPS

INSTRUMENT ILLUMINATION

Renew

the bulbs

Renew bulbs

1.

Disconnect the battery.

1

Disconnect the battery.

2.

Remove two screws and withdraw the warning

2.

Remove the four screws retaining the

light module from the front of the instrument

instrument panel.

panel.

3.

Ease forward the panel

to

gain access to the

3.

Pull off the plug connector to give access to

bulbs.

warning light bulbs,

If necessary, disconnect the drive cable from the

4.

Twist the bulb holder and pull it from its

back o f the speedometer.

socket.

4. Twist the bulb holder and pull

it

from its

5.

Pull the bulb from the holder.

socket.

6.

Fit

a

new bulb and refit the holder and plug

connector.

6.

Fit a new bulb and refit the holder.

7 . Refit the module.
8

Connect the battery.

7 .

Replace the instrument panel.

5 . Pull the bulb from its holder.

8.

Connect the battery.

REISSUED: FEB

1993

17

ELECTRICAL EQUIPMENT

WIPER MOTOR

-

OVERHAUL

INSPECTION AND

TEST

DISMANTLE

14. Check the brushes for excessive wear, if they

1.

Remove the wiper motor and drive from the

are worn to 4,8 mm in length, fit a new brush

vehicle.

gear assembly.

2.

Remove the wiper motor gearbox cover.

15.

Using a push type gauge, check that the

3. Remove the circlip and plain washer securing

brush spring pressure

IS

140

to 200 g when

the connecting rod.

the bottom of the brush

is

level with the

4.

Withdraw the connecting rod.

bottom of the slot in the brush box. Fit

a

new

5 . Withdraw the flat washer.

brush gear assembly if the springs are not

6. Remove the circlip and washer securing the

satisfactory.

shaft and gear.

16. Test the armature for insulation and open or

7.

Clean any burrs from the gear shaft and

short-circuits. Use a

110

V 15

W

test lamp. Fit

withdraw the gear.

a new armature if faulty.

8.

Withdraw the dished washer.

17. Examine the gear wheel for damage or

9. Add alignment marks to the yoke and gearbox

excessive wear.

for reassembly.

10.

Remove the yoke securing bolts.

11.

Withdraw the yoke and armature.

12.

Remove the brush gear assembly.

13. Remove the limit switch.

18

REISSUED: FEB 1993

ELECTRICAL EQUIPMENT

ASSEMBLE

Use Ragosine Listate Grease to lubricate the gear

wheel teeth, armature shaft worm gear, Connecting

rod and pin, cable rack and wheelbox gear wheels.
Use Shell Turbo

41

oil

sparingly to lubricate the

bearing bushes, armature shaft bearing journals,
gear wheel shaft and wheelbox spindles. Thoroughly
soak the felt washer in the yoke bearing with oil.

20. Fit the armature to gearbox

using

KEY TO WIPER MOTOR COMPONENTS

alignment marks, secure

with

the

yoke

retaining bolts tightening to 23 Kg f cm. If a
replacement armature is being fitted slacken

the thrust screw to provide end-float for fitting

21. Fit the dished washer beneath the gear wheel

with the concave side towards the gear wheel.

22. Fit the gear wheel to the gearbox.
23. Secure the gear wheel shaft with the plain

washer and circlip.

10.

Yoke securing bolts

24. Fit the larger flat washer over the crankpin.

25. Fit the connecting rod and secure with the

11. Armature and yolk

12. Brush gear assembly

smaller plain washer and circlip.

13. Limit switch

26.

Fit the gearbox cover and secure with the
retaining screws.

27. Connect the electrical leads between the

wiper motor and limit switch.

28.

To

adjust the armature shaft end-float, hold

the yoke vertically with the adjuster screw
uppermost. Carefully screw-in the adjuster
until resistance is felt, then back-off one
quarter turn.

1 . Flexible drive

2. Gearbox cover

3.

Connecting-rod retaining washer and circlip

4. Connecting-rod
5.

Fiat washer

6.

Gear shaft retaining washer and circlip

7 .

Drive gear

8.

Dished washer

9.

Alignment marks

-

yoke

to

body

REISSUED: FEB 1993

19

18. Fit the limit switch.
19. Fit the brush gear assembly.

the yoke.