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

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