Defender 300Tdi (1996+). Instruction - page 65

FRONT SUSPENSION

1

REPAIR

SELF LOCKING NUTS

WARNING: Where self locking nuts are
removed, they must be replaced with new
nuts of same specification.

PANHARD ROD

Service repair no - 60.10.07.

Remove

1. Remove fixings at mounting arm.
2. Remove fixings at axle bracket.
3. Remove panhard rod.
4. Using a suitable length of steel tubing, press out

flexible bushes. Ensure tubing locates on outer
edge of bush and not on rubber inner.

Refit

5. Fit replacement bushes.

CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.

6. Fit panhard rod to axle bracket and mounting

arm. Tighten fixings to

88 Nm (65 lbf/ft).

RADIUS ARM

Service repair no - 60.10.16.

Remove

1. Loosen road wheel retaining nuts.
2. Raise front of vehicle. Support chassis on stands

and remove wheel.

3. Support front axle weight with jack.
4. Remove radius arm to chassis side member

fixings.

5. Disconnect track rod at ball joint.

60

FRONT SUSPENSION

2

REPAIR

REV: 09/97

6. Remove fixings, radius arm to axle.
7. Lower radius arm front end to clear axle and

remove from vehicle.

8. Using suitable length of steel tubing, press out

flexible bushes.

Refit

9. Press in replacement bushes.

CAUTION: When pressing in new bushes
press on outer edge of bush and not
rubber inner.

10. Fit radius arm to axle mounting.
11. Fit track rod at ball joint.
12. Fit radius arm to chassis. Tighten bolts to

176

Nm (130 lbf/ft).

13. Fully tighten radius arm to axle fixings to

197 Nm

(145 lbf/ft).

14. Fit road wheel, remove chassis stands and jack.

Tighten wheel nuts to correct torque:
Alloy wheels -

130 Nm (96 lbf/ft)

Steel wheels -

100 Nm (80 lbf/ft)

Heavy duty wheels -

170 Nm (125 lbf/ft)

FRONT SHOCK ABSORBER

Service repair no - 60.30.02.

Remove

1. Loosen road wheel retaining nuts.
2. Support chassis on stands and remove road

wheel.

3. Support axle weight with jack.

4. Remove shock absorber lower fixing and

withdraw cupwasher, rubber bush and seating
washer.

5. Remove four shock absorber bracket fixings.

6. Withdraw shock absorber and bracket assembly.
7. Withdraw lower seating washer, rubber bush and

cupwasher.

8. Remove fixings, shock absorber to mounting

bracket.

9. Withdraw mounting bracket.

10. Lift off top seating washer, rubber bush and

cupwasher.

FRONT SUSPENSION

3

REPAIR

REV: 09/97

Refit

11. Assemble shock absorber components.
12. Position shock absorber, complete with bracket

and secure with 4 fixings.

13. Secure shock absorber lower fixing.
14. Fit road wheel, remove chassis stands and jack.

Tighten wheel nuts to correct torque:
Alloy wheels -

130 Nm (96 lbf/ft)

Steel wheels -

100 Nm (80 lbf/ft)

Heavy duty wheels -

170 Nm (125 lbf/ft)

FRONT ROAD SPRING

Service repair no - 60.20.11.

Remove

1. Remove front shock absorber

See Front

shock absorber .

CAUTION: Avoid over stretching brake
hoses. If necessary, loosen hose
connector locknuts to allow hoses to

follow axle.

2. Lower axle sufficient to free road spring.

3. Withdraw road spring.
4. Withdraw shock absorber bracket securing ring.

Refit

5. Fit shock absorber bracket retaining ring. Retain

in position with a nut.

6. Position road spring and raise axle.
7. Remove nut retaining securing ring.
8. Fit front shock absorber

See Front shock

absorber .

60

FRONT SUSPENSION

4

REPAIR

BUMP STOP

Service repair no - 60.30.10.

Remove

1. Remove fixings.
2. Remove bump stop.

NOTE: A chassis undertray may be fitted
on some vehicle derivatives to conform to
legal requirements. When under chassis

remove and refit procedures are required, it may
be necessary to remove the undertray

See

CHASSIS AND BODY, Repair, Front undertray .

Refit

3. Position bolts in slots in chassis brackets.
4. Fit bump stop, secure with washers and nuts.

ANTI-ROLL BAR

Service repair no - 60.10.01

Remove

1. Mark for reassembly position of rubber bushes

on anti-roll bar.

2. Remove 4 nuts, bolts and washers securing both

anti-roll bar bush straps to chassis mounting
brackets.

3. Remove nuts, bolts, washers and rubber bushes

securing anti-roll bar to both links

4. Remove anti-roll bar.

Refit

5. Position bushes on anti-roll bar. Ensure split

points towards axle on RH bush and away from
axle on LH bush.

6. Fit anti-roll bar with two straps. To ensure correct

fit angled sides of bar should point down.
Loosely fit the bolts, washers and nyloc nuts.

7. Fit bolt, washers and rubber bushes. Using new

nuts fit anti-roll bar to links and tighten to

68Nm

(50 lbf/ft).

8. Tighten nuts securing straps to

30Nm (22lbf/ft).

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