Defender 300Tdi (1996+). Manual — part 59
STEERING
3
REPAIR
NOTE: The steering column is a non
servicable component and can only be
serviced as a complete assembly.
25. Fit main support bracket and padding to steering
column and manoeuvre column into position in
vehicle.
26. Loosely secure main support bracket and
harness bracket to bulkhead.
27. Loosely fit clamp and rubber packing strip to
column.
28. Loosely secure lower end of column to lower
support bracket.
29. Loosely secure clamp bracket to main support
bracket.
30. Working inside vehicle cab, fit tie-bar to column
bracket and secure with single bolt to
22 Nm (16
lbf/ft).
31. Finally, tighten main support bracket, clamp
bracket, upper clamp, and lower support bracket
nuts and bolts. (M6 bolts
9 Nm (6 lbf/ft) , M8
bolts
22 Nm (16 lbf/ft).
32. Fit brake pedal box
See BRAKES, Repair,
Brake pedal .
33. Fit steering lock/switch in position and rotate
steering column inner shaft to line up slot with
switch plunger.
34. Secure lock to column with clamp and shear
bolts. Evenly tighten bolts but do not shear them.
35. Temporarily fit steering wheel and operate
switch and lock mechanism several times to
ensure it functions correctly.
36. Fully tighten switch retaining bolts until heads
shear.
37. Connect electrical leads to rear of switch. Fit
alarm system passive coil, if applicable.
See
ELECTRICAL, Repair, Vehicle immobilisation
and alarm system
38. Fit switch assembly on steering column and
tighten clamping screw.
39. Connect switch assembly multi-plugs and
electrical leads to main harness.
40. Offer up instrument panel, connect speedometer
cable, multi-plugs and electrical leads to main
harness. If applicable, fit vehicle alarm system
connections.
See ELECTRICAL, Repair,
Vehicle immobilisation and alarm system .
41. Secure panel with 4 screws.
42. Locate top half of nacelle in position and fit to
switch gaiters/grommets.
43. Fit lower half of nacelle and loosely tighten fixing
screws.
44. Ensure switch gaiters/grommets are correctly
located and fully tighten fixings.
45. Turn indicator cancelling ring so that slots are
vertical and lug with arrow points to the left, in
direction of indicator switch.
46. Fit steering wheel with finisher attachment lug at
bottom, ensuring that indicator cancelling forks
locate in cancelling ring slots.
47. Secure wheel with nut and new shake-proof
washer. Tighten to
50 Nm (37 lbf/ft).
48. Fit steering wheel decal.
49. If necessary, fit new universal joints to support.
Note that long joint is fitted to short length of
shaft and short joint to long end. Joints can only
be fitted one way to shaft.
50. With steering lock engaged and road wheels in
straight ahead position, align reassembly marks,
and fit collapsible shaft assembly with long leg of
shaft to steering box. Fit pinch bolts and tighten
to
25 Nm (18 lbf/ft).
57
STEERING
4
REPAIR
POWER STEERING BOX
Service repair no - 57.10.01
NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis
remove and refit procedures are required, it may
be necessary to remove the undertray
See
CHASSIS AND BODY, Repair, Front undertray .
General precautions
Whenever any part of system, is removed or
disconnected, utmost cleanliness must be
observed.
Disconnected ports and hoses must be
plugged to prevent ingress of dirt. If metal
sediment is found in system, establish cause,
rectify and flush system.
Do not start engine until reservoir is full as
pump will be damaged.
Metric pipe fittings are used with ’O’ ring pipe
ends on fittings to steering box.
Follow normal ’O’ ring replacement procedure
whenever pipes are disconnected.
Ensure compatible metric components when
fitting replacement pipes.
CAUTION: After refitting steering linkage
parts follow correct procedure to ensure
that road wheels, steering box and
steering wheel are correctly positioned relative to
each other when in straight ahead condition.
NOTE: When drag link is disconnected
from steering box, travel available at
steering wheel to each full lock is not
equal.
Remove
1. Site vehicle on level surface.
2. Apply park brake, chock rear wheels, raise
vehicle and locate axle stands. Alternatively,
raise vehicle on a hoist.
3. Remove road wheel.
4. Remove panhard rod
See FRONT
SUSPENSION, Repair, Panhard rod .
5. Disconnect steering damper from drag link.
6. Disconnect drag link from drop arm, see J6305
on opposite page, using a suitable extractor.
7. Slacken, but do not remove nut securing tie bar
to mounting arm.
8. Remove 2 bolts securing tie bar to steering box
and move aside.
9. Remove filler cap from power steering fluid
reservoir.
10. Position suitable container under steering box.
11. Disconnect feed and return pipes from steering
box and drain fluid.
12. Plug open pipes and steering box ports to
prevent ingress of dirt. Refit fluid reservoir filler
cap.
13. Centralise steering
See Centralise steering
box .
14. Remove pinch bolt securing lower shaft
universal joint to power steering box.
15. Remove 4 bolts and 2 tab washers securing
steering box to chassis side member.
16. Withdraw steering box.
17. Clean all mounting faces, unions etc. prior to
refitting.
Refit
18. Position steering box to chassis side member,
ensuring locating peg is engaged. Fit tab
washers and tighten bolts to
81 Nm (60 lbf/ft).
19. Fit pinch bolt and nut securing universal joint to
power steering box spline. Tighten to
25 Nm (18
lbf/ft).
20. Secure tie bar to mounting arm and steering box.
Tighten fixings to
81 Nm (60 lbf/ft), starting with
tie bar to mounting nut, then loosen fixings by
one complete turn.
21. Check steering box and adjust if necessary
See
Adjustment, Power steering box - adjust .
22. Refit drag link to drop arm and tighten nut to
40
Nm (30 lbf/ft). Fit new split pin to retaining nut.
STEERING
5
REPAIR
REV: 09/97
23. Fit panhard rod
See FRONT SUSPENSION,
Repair, Panhard rod .
24. Fit road wheels. Lower vehicle to ground and
tighten wheel nuts 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)
25. Remove plugs and refit feed and return pipes to
steering box. Tighten 16mm thread to
20 Nm (15
lbf/ft), 14mm thread to 15 Nm (11 lbf/ft).
26. Remove filler cap. Fill reservoir to oil level mark
on dipstick, using recommended fluid
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended lubricants and
fluids .
27. Bleed power steering system
See Power
steering system - bleed .
28. Recheck fluid level and replace cap.
29. With engine running, test steering system for
leaks by holding steering in both full lock
directions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute, to avoid oil overheating and
possible seal damage.
30. Test drive vehicle: using both full lock directions,
to settle steering components. If possible, drive
vehicle over uneven ground and include harsh
braking.
WARNING: Do not test drive vehicle on
public highway.
31. Drive vehicle in a straight line on level ground
and stop.
32. Tighten tie bar to mounting nut to
110 Nm (81
lbf/ft).
33. Tighten tie bar to steering box fixings to
81 Nm
(60 lbf/ft).
34. Ensure steering wheel is correctly aligned when
wheels are positioned straight ahead.
35. If necessary, reposition steering wheel
See
Steering wheel .
36. Road test vehicle.
57
STEERING
6
REPAIR
POWER STEERING SYSTEM - BLEED
Service repair no - 57.15.02
1. Check that fluid level is at maximum level
See
MAINTENANCEMaintenance Under bonnet
maintenance .
2. Run engine to normal operating temperature.
3. Recheck reservoir fluid level, top up if necessary
NOTE: During operations 4 to 6, maintain
maximum fluid level in reservoir. Do not
increase engine speed or move steering
wheel.
4. With engine at idle speed, slacken bleed screw.
When fluid seeps past bleed screw retighten
screw.
5. Check fluid level.
6. Clean away fluid around bleed screw.
7. Check hose connections, pump and steering box
for fluid leaks by holding steering on full lock in
both directions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute to avoid overheating fluid and
possibly damaging seals.
8. Carry out road test.
POWER STEERING FLUID RESERVOIR
Service repair no - 57.15.08
Remove
1. Position drain tin beneath reservoir.
2. Slacken mounting bracket clamp bolt and raise
reservoir to gain access to feed and return hose
retaining clips.
3. Slacken clips, disconnect hoses from reservoir,
allow fluid to drain.
4. Remove reservoir.
CAUTION: Plug connections to prevent
ingress of dirt.
CAUTION: Discard fluid drained from
system. Do not allow fluid to contact
paintwork, if spilled, remove fluid and
clean area with warm water.
Refit
5. Position reservoir, connect feed and return
hoses and tighten clips to
3 Nm (2 lbf/ft).
6. Fit reservoir in clamp, tighten clamp bolt.
7. Fill reservoir between upper mark and end of
dipstick with power steering fluid
See
MAINTENANCEMaintenance Under bonnet
maintenance .
8. Bleed power steering system
See Power
steering system - bleed .
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