Defender 300Tdi (1996+). Instruction - page 53
FRONT AXLE AND FINAL DRIVE
5
OVERHAUL
38. Place retaining plate, joint washer and oil seal
over axle flange ready for assembly.
39. Fit swivel bearing housing to axle flange with 7
bolts. Tighten to
73 Nm (54 lbf/ft).
40. Grease and fit upper and lower swivel pin taper
roller bearings.
41. Position swivel pin housing over swivel bearing
housing.
42. Coat joint washer both sides with sealing
compound and position on lower swivel pin.
43. Loosely fit brake shield bracket plus lower swivel
pin with lug outboard to swivel pin housing.
44. Loosely fit top swivel pin plus existing shims and
brake hose bracket to swivel pin housing.
45. Apply Loctite 270 or equivalent to lower swivel
pin bolts.
78 Nm (58 lbf/ft), bend over lock tabs.
46. Tighten top swivel pin bolts to
78 Nm (58 lbf/ft).
Check and adjust preload on bearings
NOTE: Swivel housing oil seal and axle
should not be fitted.
47. Attach a spring balance to ball joint bore and pull
balance to determine effort required to turn
swivel pin housing.
Resistance, once initial inertia has been
overcome, should be 1.16 to 1.46 kg. Adjust by
removing or adding shims to top swivel pin.
48. When setting is correct remove top swivel bolts,
apply Loctite 270 or equivalent. Refit bolts and
tighten to
78 Nm (58 lbf/ft), and bend over lock
tabs.
49. Apply recommended grease between lips of
swivel oil seal.
50. Fit oil seal, joint washer and retaining plate with
7 bolts and spring washers. Tighten to
11 Nm (8
lbf/ft).
51. Fit tie rod and drag link and secure with new
cotter pins. Tighten fixing to
40 Nm (30 lbf/ft).
52. Fit brake disc shield.
53. Loosely fit lock stop bolt and nut.
54. Apply a recommended grease between lips of
swivel housing oil seal.
55. Secure oil seal with retaining plate and securing
bolts. Tighten to
11 Nm (8 lbf/ft).
56. Fit track-rod and drag link and secure with new
cotter pins.
57. Loosely fit lock stop bolt for later adjustment.
58. Fit brake disc shield.
Fit driveshaft and stub axle
59. Insert axle shaft, and when differential splines
are engaged, push assembly in fully.
CAUTION: Take care not to damage axle
shaft oil seals.
60. Place a new joint washer in position on swivelpin
housing to stub axle mating face. Coat threads
of stub axle bolts with Loctite 270.
61. Fit stub axle with flat at 12 O’clock position.
CAUTION: Ensure that constant velocity
joint bearing journal is butted against
thrust ring on stub axle before stub axle is
secured.
62. Place mud shield in position and secure stub
axle to swivel pin housing with 6 bolts and
tighten evenly to
65 Nm (48 lbf/ft).
63. Fit brake jump hoses to brake jump hose
bracket.
64. Fit complete front hub assembly
See Repair,
Front hub assembly .
65. Check swivel pin housing oil drain plug is fitted.
66. Fill swivel assembly to correct level, with new oil
See SECTION 10, Maintenance, Under
vehicle maintenance .
NOTE: On later vehicles fill swivel pin
housing with 0.33 Litres of Molytex EP 00
grease.
67. Set steering lock stop bolts
See STEERING,
Adjustment, Steering lock stops .
FRONT AXLE AND FINAL DRIVE
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
FRONT AXLE
Hub driving member to hub
65*
.......................................................................
Brake disc to hub
73
.......................................................................................
Stub axle to swivel pin housing
65*
.................................................................
Brake caliper to swivel pin housing
82
............................................................
Upper swivel pin to swivel pin housing
78*
.....................................................
Lower swivel pin to swivel pin housing
78*
.....................................................
Oil seal retainer to swivel pin housing
11
........................................................
Swivel bearing housing to axle case
73*
.........................................................
Pinion housing to axle case
41
.......................................................................
Crown wheel to differential housing
58
...........................................................
Differential bearing cap to pinion housing
90
..................................................
Differential drive flange to drive shaft
47
.........................................................
Mudshield to bracket lower swivel pin
11
........................................................
Bevel pinion nut
130
........................................................................................
Draglink to hub arm
40
....................................................................................
Panhard rod to axle bracket
88
.......................................................................
Radius arm to axle
190
....................................................................................
Radius arm to chassis side member
190
.........................................................
NOTE: * These bolts to be coated with Loctite 270 prior to assembly.
STEERING
1
DESCRIPTION AND OPERATION
DESCRIPTION
The steering system incorporates a compression joint
in the lower shaft and is designed to collapse on
impact. The mis-alignment of the upper steering
column with the steering box and the inclusion of two
universal joints, is also designed to prevent the
column moving toward the driver under frontal impact.
The steering box is located behind the first chassis
cross member and is connected to the road wheel
swivel housing by a drag link and track rod. A
hydraulic damper absorbs shocks in the steering,
caused by road wheel deflections when operating on
rough terrain.
Power steering system
The power steering system comprises a hydraulic
pump which is belt driven from the engine and
supplied with fluid from a reservoir that also acts as a
cooler.
The steering box houses a self neutralizing rotary
valve which is part of the worm/valve assy and an
hydraulic piston/rack to assist the mechanical
operation. The rotary valve which is operated by
movement of the steering wheel, directs fluid pressure
to the appropriate side of the hydraulic piston/rack to
provide assistance.
Power steering system
1. Hydraulic pump
2. Fluid reservoir
3. Steering box
4. Upper column
5. Universal joints
6. Lower shaft
7. Compression joint
8. Drag link
57
STEERING
2
DESCRIPTION AND OPERATION
Power steering box components
1. Housing complete with sector shaft bearings
2. Cover plate complete with bearing
3. Sector shaft
4. Hydraulic piston/rack
5. Worm/valve and torsion bar assembly
6. Shims for centralizing worm/valve
7. Ball race
8. ’Teflon’ seals for valve sleeve
9. Bearing adjuster, locknut and seal
10. Worm shaft pressure seal, circlip and dirt
excluder
11. ’Teflon’ and rubber seal for piston
12. End cover seal and snap ring
13. Adjustment components for piston/rack
14. Hydraulic pipe
15. Bleed screw
16. Sector shaft adjustment lock nut with seal
17. Cover plate bolts
18. Cover plate seal
19. Seal, washer and backup seal
20. Circlip and dust cover