Defender 300Tdi (1996+). Manual — part 64
57
STEERING
8
OVERHAUL
84. Refit locknut and tighten.
NOTE: It is important steering box is
centralised before any adjustments are
made.
85. Check maximum rolling torque one and a quarter
turns either side of centre position, using a
torque wrench and spline socket LRT-57-025.
Rotate adjuster screw to obtain across centre
torque of 0.34 Nm plus torque figure at one and
a quarter turns. Tighten adjuster locknut to
60
Nm (44 lbf/ft).
Adjusting rack adjuster.
86. Turn in rack adjuster to increase figure
measured in instruction 85. by 0.23 - 0.34 Nm.
The final figure may be less, but must not
exceed 1.35 Nm.
87. Lock rack adjuster in position with grub screw.
Tighten to
5 Nm (4 lbf/ft).
Torque peak check
With input shaft rotated from lock to lock, rolling
torque figures should be greatest across centre
position and equally disposed about centre position.
The condition depends on value of shimming fitted
between valve and worm assembly inner bearing cup
and casing. The original shim washer value will give
correct torque peak position unless major components
have been replaced.
Procedure
88. With input coupling shaft toward the operator,
turn shaft fully counter-clockwise.
89. Check torque figures obtained from lock to lock
using torque wrench and spline socket
LRT-57-025.
90. Check also for equal engagement either side of
centre.
Adjustments
91. Note where greatest figures are recorded
relative to steering position.If greatest figures are
not recorded across centre of travel (steering
straight-ahead), adjust as follows:
If torque peak occurs before centre position, add to
shim washer value; if torque peak occurs after centre
position, subtract from shim washer value,
refer to
fitting valve and worm assembly .
Shim washers are available as follows:
0.03mm, 0.07mm, 0.12mm and 0.24mm.
NOTE: Adjustment of 0.07mm to shim
value will move torque peak area by 1/4
turn on the shaft.
CAUTION: When reshimming valve and
worm, extreme caution must be exercised
to prevent seal damage during
reassembly.
STEERING
9
OVERHAUL
Input shaft oil seal
92. Fit seal, lip side first, into housing. Use seal
saver LRT-57-016 and seal installer
LRT-57-026. Note that seal is fitted to a depth of
4.75 - 5.00 mm from face of box.
93. Secure seal with circlip.
94. Smear inner lip of dirt excluder with PTFE
grease. Fit dirt excluder using LRT-57-027.
When fitted correctly outer shoulder of excluder
is 4.00 - 4.50 mm from face of box, dimension X.
95. Remove drop arm. Smear inner lip of dirt
excluder with PTFE grease and refit, ensuring
outer lip is flush with casing.
96. With input shaft on centre, align assembly marks
on drop arm and steering box. Fit drop arm to
steering box using a new tab washer. Tighten to
176 Nm (130 lbf/ft), bend over tab.
97. Fit steering box
See Repair, Power Steering
Box .
STEERING
1
SPECIFICATIONS, TORQUE
TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Ball joint nuts
40
. . . . . . . . . . . . . . . . . . . . . . . ..
Clamp bolt nuts
9
. . . . . . . . . . . . . . . . . . . . . . ...
Steering column bracket nuts
22
. . . . . . . . . . . . . . . . .
Steering wheel nut
50
. . . . . . . . . . . . . . . . . . . . . .
Tie bar to mounting nut
110
. . . . . . . . . . . . . . . . . . . .
Universal joint pinch bolt
25
. . . . . . . . . . . . . . . . . . .
PAS box
Adjuster locknut
60
. . . . . . . . . . . . . . . . . . . . .
Drop arm nut
176
. . . . . . . . . . . . . . . . . . . . .
Sector shaft cover to steering box
75
. . . . . . . . . . . . . .
Steering box to chassis
81
. . . . . . . . . . . . . . . . . .
Steering box fluid pipes 14mm thread
15
. . . . . . . . . . . ...
Steering box fluid pipes 16mm thread
20
. . . . . . . . . . . ...
Tie bar
81
. . . . . . . . . . . . . . . . . . . . . . . ...
PAS pump
High pressure fluid pipe
20
. . . . . . . . . . . . . . . . . .
Power steering pump mounting
35
. . . . . . . . . . . . . . .
Pulley bolts, power steering pump
10
. . . . . . . . . . . . .
Hose clamp
3
. . . . . . . . . . . . . . . . . . . . . .
Front mounting plate bolts
9
. . . . . . . . . . . . . . . . ..
PAS reservoir
Hose clamp
3
. . . . . . . . . . . . . . . . . . . . . .
* Torque values below are for all screws and bolts used except for those that are specified otherwise.
METRIC
Nm
M5
6
. . . . . . . . . . . . . . . . . . . . . . . . . ..
M6
9
. . . . . . . . . . . . . . . . . . . . . . . . . ..
M8
25
. . . . . . . . . . . . . . . . . . . . . . . . . .
M10
45
. . . . . . . . . . . . . . . . . . . . . . . . ...
M12
90
. . . . . . . . . . . . . . . . . . . . . . . . ...
M14
105
. . . . . . . . . . . . . . . . . . . . . . . . ..
M16
180
. . . . . . . . . . . . . . . . . . . . . . . . ..
UNC / UNF
1/4
9
. . . . . . . . . . . . . . . . . . . . . . . . . ..
5/16
24
. . . . . . . . . . . . . . . . . . . . . . . . ...
3/8
39
. . . . . . . . . . . . . . . . . . . . . . . . . .
7/16
78
. . . . . . . . . . . . . . . . . . . . . . . . ...
1/2
90
. . . . . . . . . . . . . . . . . . . . . . . . . .
5/8
136
. . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SUSPENSION
1
DESCRIPTION AND OPERATION
DESCRIPTION
The front suspension design allows maximum wheel
travel and axle articulation providing good ground
clearance without loss of traction or directional
stability.
Long radius arms are fitted to the front axle and
provide maximum axle articulation which is vital for off
road performance. The radius arms are secured to
fabricated mounting brackets welded to the front axle.
Flexible rubber bushes are used on a stem end joint
to secure the rear of the radius arms to mountings on
the chassis cross member.
A panhard rod, which ensures that the front axle
remains centrally located, is fitted transversely and
also uses ferrule rubber bush mountings at both axle
and chassis locations.
Two rubber bearing bushes, with retaining straps,
secure the rear of the anti-roll bar to the chassis
mountings, while bushed links support the front of the
bar to the front axle.
Conventional long travel coil springs and hydraulic
shock absorbers are used to control body movement
in all conditions. The shock absorbers are secured to
fabricated towers which are bolted to the chassis. The
upper and lower fixings use a single location stud with
flexible rubber bushes, support washers and securing
nuts. Retaining plates are used to secure the coil
springs to the fabricated towers and axle mountings.
Rubber bump stops are fitted underneath the chassis,
adjacent to the front road springs, and prevent
possible damage that could occur should there be
excessive axle to chassis movement.
Front suspension
1. Panhard rod
2. Radius arms
3. Coil springs
4. Shock absorber
5. Anti-roll bar
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