Defender. Manual — part 14
Item
Part Number
Description
A
-
Front and rear axle - 90 models; Front - 110/130 models
B
-
Rear axle - 110/130 models
3. If necessary inject new oil until oil runs out from filler/level hole. Allow excess oil to drain and wipe clean.
For additional information, refer to:
Specifications
(205-02 Rear Drive Axle/Differential, Specifications).
4. Clean and refit filler/level plug.
Replace
WARNING: Avoid excessive skin contact with used axle oil. Used axle oil contains potentially harmful contaminants
which may cause skin cancer or other serious skin disorders.
1. Make sure vehicle is level and place suitable tray under axle to be drained.
2. Using 13mm square drive wrench, remove drain and filler/level plugs from axle and allow oil to drain completely.
3. Clean and refit drain plug.
4. Inject new oil, until it runs out from filler/level hole. Allow excess oil to drain and wipe clean.
5. Clean and refit filler/level plug.
Drive Shafts
1. Clean area around front universal joint grease nipple.
2. Apply recommended grease to the grease nipple.
Clutch Pipes and Unions
1. Check clutch pipes and unions for chafing, leaks and corrosion.
Power Steering Pipes and Unions
1. Check clutch pipes and unions for chafing, leaks and corrosion.
Engine, Gearbox, Transfer Case and Axles
1. Check for oil leaks from Engine, Gearbox, Transfer box, and axles. Pay particular attention to areas around oil seals.
Exhaust System
1. Visually check condition of exhaust system for signs of damage.
2. Check condition of exhaust heat shields.
3. Check exhaust system is firmly secured and check condition of exhaust mounting rubbers, clamps and brackets.
Steering Box and Suspension
1. Check steering box fixings.
For additional information, refer to:
Specifications
(204-00 Suspension System - General Information, Specifications).
2. Check LH and RH front radius arm fixings. Tighten if necessary.
For additional information, refer to:
Specifications
(204-00 Suspension System - General Information, Specifications).
3. Check Panhard rod fixings. Tighten if necessary.
For additional information, refer to:
Specifications
(204-00 Suspension System - General Information, Specifications).
4. Check all rear axle fixings. Tighten if necessary.
For additional information, refer to:
Specifications
(205-02 Rear Drive Axle/Differential, Specifications).
Steering Ball Joints
1. Check for wear in joints by attempting to move the joint from side to side and backwards and forwards. If free
movement is apparent, fit a new joint assembly.
CAUTION: Do not check for wear by having an assistant move the steering wheel from side to side while observing
the joint.
2. Check condition of steering ball joints paying particular attention to dust covers.
• NOTE: Any requirement to replace the steering ball joints should be advised to the customer as this will incur
additional labour and/or material cost and should not be carried out without the authorisation of the customer.
• NOTE: Ball joints are lubricated for life during manufacture and require no further lubrication unless the rubber boot
has been dislodged or damaged. All joints should be checked at specified service intervals, but more frequently if vehicle
is used under arduous conditions.
Shock Absorbers
1. Check for signs of leakage from suspension dampers.
2. Check for signs of suspension damper damage.
Towing Bracket
1. Check security of towing bracket.
Engine and Transmission Mountings
1. Check condition of front LH engine mounting. Tighten fixings if necessary.
For additional information, refer to:
Specifications
(303-01 Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
Specifications).
2. Check condition of front RH engine mounting. Tighten fixings if necessary.
For additional information, refer to:
Specifications
(303-01 Engine - 2.4L Duratorq-TDCi HPCR (103kW/140PS) - Puma,
Specifications).
3. Check condition of rear LH gearbox mounting. Tighten fixings if necessary.
For additional information, refer to:
Specifications
(308-03 Manual Transmission/Transaxle, Specifications).
4. Check condition of rear RH gearbox mounting. Tighten fixings if necessary.
For additional information, refer to:
Specifications
(308-03 Manual Transmission/Transaxle, Specifications).
Road Test
WARNING: Two wheel roller tests where rollers are driven by the vehicle MUST NOT be carried out. For details of
rolling road testing,
1. Check for correct operation of starter switch. Make sure the engine starts in a correct manner. Leave the engine
running.
2. With vehicle stationary, turn steering from lock to lock. Check for smooth operation and make sure there is no undue
noise from the power steering pump or drive belt.
3. Depress clutch and select all gears in turn. Check for smooth notch free engagement.
4. Drive vehicle on a short road test. Check all vehicle systems for correct operation. Pay particular attention to:
Manual gear selection.
Gear selection/noise - high/low range.
Steering for abnormal noise/effort.
Steering for free play.
Engine noise
Gearbox noise or vibration
Suspension noise or irregularities
Body noise
Braking system operation
Engine performance
Excessive exhaust smoke.
All instruments, gauges and warning indicators.
Heater and air conditioning systems.
Fully extend seat belt, check operation of retraction and latching. Inertia belts lock when snatched or vehicle on
slope.
Seat reclining and latching.
5. Check for correct operation of all instruments and warning devices where practical.
6. After road test, carry out a final inspection of the vehicle on vehicle ramps.
7. Check all underbonnet fluid levels and top-up if necessary.
General
1. Endorse Service Record.
2. Report any unusual features of vehicle condition and any additional work required.
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