Defender. Manual — part 55
3. Secure the power steering fluid reservoir.
Tighten to 4 Nm (3 lb.ft).
4. Tighten to 23 Nm (17 lb.ft).
5. NOTE: Remove and discard the blanking caps.
• NOTE: Install a new O-ring seal.
Connect the power steering high-pressure pipe union.
Tighten to 20 Nm (15 lb.ft).
6. Secure the accessory drive belt.
Rotate the accessory drive belt tensioner clockwise.
7. Install the cooling fan.
For additional information, refer to:
Cooling Fan
(303-03
Engine Cooling - 2.4L Duratorq-TDCi HPCR (103kW/140PS) -
Puma, Removal and Installation).
8. Connect the battery ground cable.
For additional information, refer to:
Battery Connect
(414-01
Battery, Mounting and Cables, General Procedures).
9. Fill and bleed the power steering system.
For additional information, refer to:
Power Steering System
Filling and Bleeding
(211-00 Steering System - General
Information, General Procedures).
Power Steering - Steering Gear
Disassembly and Assembly
Disassembly
WARNING: Wear safety glasses while removing and refitting circlips and retaining ring.
CAUTION: Absolute cleanliness is essential when overhauling steering gear.
• NOTE: Overhaul of steering gear should not be carried out during the warranty period.
• NOTE: This procedure is for Adwest steering gear only.
1. Remove steering gear from vehicle.
For additional information, refer to:
Steering Gear
(211-02
Power Steering, Removal and Installation).
Mark drop arm and steering gear for realignment on
assembly. Remove drop arm using extractor LRT-57-012.
Loosen drop arm securing nut, but do not remove before
using extractor. Remove dirt excluder from output shaft.
2. Drain oil, remove blanking plugs and bleed screw. Hold
steering gear over suitable container, turn input shaft from
lock to lock, until oil is drained. Refit bleed screw.
3. Rotate retainer ring until one end is 12 mm from extractor
hole. Using a drift through hole in cylinder, lift retaining ring
from groove in cylinder bore.
4. Remove retainer ring, using a screwdriver.
5. Turn input shaft (left lock on left hand drive vehicles, right
lock on right hand drive vehicles) until piston pushes out
cover. Turn input shaft fully in opposite direction, applying
pressure to piston.
6. Remove set screw retaining rack pad adjuster.
7. Remove rack adjuster and pad.
8. Remove sector shaft adjuster locknut.
9. Remove four bolts from sector shaft cover.
10. Screw in sector shaft adjuster until cover is removed.
11. Slide out sector shaft.
12. Remove piston, a bolt screwed into piston will assist
removal.
13. Remove input shaft dirt excluder.
14. Remove worm adjuster locknut using 'C' wrench LRT-57-
007.
15. Remove worm adjuster using wrench LRT-57-006.
16. Tap splined end of shaft to free bearing.
17. Remove bearing cup and caged ball bearing assembly.
18. Remove valve and worm assembly.
19. NOTE: If difficulty is experienced warm the casing and
bearing assembly. Cool bearing cup using a mandrel and tap
steering gear on a bench.
Remove inner bearing cage, cup and shim washers. Retain
shims for reassembly.
20.
CAUTION: Do not remove sector shaft bearings from
casing. Replacement parts are not available. If sector shaft
bearings are worn fit a new steering gear.
Remove circlip and seal from sector shaft housing bore.
21.
CAUTION: The use of a seal puller is recommended
to prevent damage to casing, resulting in possible oil leaks.
Remove dirt excluder, circlip and seal from input shaft
housing bore.
22. Discard all rubber seals and obtain replacements.
• NOTE: A rubber seal is fitted behind plastic ring on rack piston. Discard seal and plastic ring.
23. Examine piston bore for scoring and wear.
24. Examine feed tube.
25. Fit a new feed tube if damaged. Tighten union to 22 Nm
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