Defender (1993+). Instruction - page 74

STEERING

Fitting sector

shaft

seal

1.

With the lipped side leading, fit the oil seal to

the casing followed by a plain fibre washer.

2.

Fit the steel backed dust seal, flat side

downwards towards the oil seal. Secure with
the

circlip ensuring that it is properly located

in the groove.

4

Fit a new sealing ring to the worm adjuster
screw and turn the adjuster clockwise into the

housing

using special tool

LST

119

until the

end float in the input shaft is almost
eliminated. Fit the lock-nut but do not tighten
until the following instructions for setting the
input shaft preload are completed.

Fitting valve and

worm assembly

1.

Fit

the inner bearing cup and the original

shims to the casing. Use a suitable bar
approximately

57

mm diameter to tap the cup

squarely into position. If the original shims are
not available fit shims to the value

of

0,76 mm

to provide a nominal thickness.

2.

Fit the inner and outer bearing cages to the
worm using petroleum jelly only

to

hold the

cages

in

position.

Do

not use grease

for

this

purpose since it does not dissolve

in

the

steering

box

lubricating fluid and could block

the fluid passages in the valve assembly.

3. Cover the input shaft splined area with seal

saver

RO 1015

and carefully insert the shaft

into the casing followed by the outer bearing
cup.

16

REISSUED:

FEB 1993

STEERING

5.

Fit the torque setting tool RO 1016 to the

input shaft and secure with the grub screw.
Coil a length of cord round the tool and attach
a spring balance to the free end. Measure and
record the rolling resistance

of

the shaft as

the spring balance is pulled.

3.

Fit seal saver R O 606604 over the thread and

splines of the sector shaft and carefully insert
the shaft into the casing. Align the centre gear
pitch on the rack with the centre gear tooth on
the sector shaft and at the same time rotate

the input shaft about a small arc to allow the
sector roller

to

engage the worm.

6,

To

settle the bearings, turn the worm adjuster

again, clockwise, to increase the resistance
over that recorded in the previous instruction
by 1.8 to

2,2

kg (at a radius of 31,7 mm which

is

determined by the setting

tool).

7. Now,

back-off

the

worm

adjuster

anti-clockwise

so

that the rolling resistance

recorded in instruction

5

is only 0,9 to 1,3 kg

Tighten the locknut using special

tool

LST

119.

Check the rolling resistance again

in

case tightening the lock-nut has altered the
setting.

Fitting

rack, piston and sector shaft

1.

Screw

a

suitable bolt into the piston crown to

assist the fitting and positioning of the piston
as was recommended for removing the piston.

2.

insert the piston, rack end first, into the casing

so

that the piston crown is approximately 63,5

mm from the outer end

of

the bore.

REISSUED:

FEB 1993

17

STEERING

4.

The illustration below shows the position in

Fitting sector shaft cover

which the sector shaft and roller should be in
relation to the casing aperature when the shaft
is being inserted.

1.

Fit and lubricate a new sealing ring to the
inside

of

the cover and screw the cover fully

on to the sector shaft adjuster screw. If
necessary, use an Allen key

to

hold the screw

to prevent it turning.

2.

Locate the cover on the casing noting that it

can only be fitted one way, that is, with the
bleed nipple towards the worm adjuster. Tap
the cover into place and if necessary, back off

the adjuster screw a few turns to allow the
cover

to

seat properly on the casing.

Fit

the

3.

Using the torque setting tool

RO

1016

for

convenience, rotate the input shaft through a
small arc, in both directions, to ensure that the
sector roller is free to move in the worm.
Tighten the four screws evenly

to

the correct

torque.

cover retaing screws but do not tighten.

Fitting

rack adjuster

1.

Fit a new sealing ring

to

the rack adjuster.

2.

Fit the adjuster pad with the flat side towards

the rack and screw

in

the

adjuster until solid

contact is made with the rack. Now back-off
the adjuster half a turn.

3.

Insert the Nylon locking pad and fit the grub

screw, leaving it slack

at

this stage.

18

REISSUED: FEB 1993

STEERING

Fitting cylinder cover

Setting the sector shaft and rack adjuster

pre-loads

1.

Fit and lubricate a new seal to the cylinder

cover and press the cover squarely into the

1.

Turn the input shaft to set the sector shaft

cylinder just far enough to clear the retaining

roller at the mid point of its travel between the

ring groove.

left and right hand locks.

2.

Secure the cover with the retaining ring by

2.

Using a 6 mm Allen key, turn the sector shaft

inserting one end of the ring into the cylinder

adjusting screw anti-clockwise to obtain

groove

so

that it is positioned 12 mm beyond

backlash between the input shaft and sector

the ring extractor hole

in

the side of the

shaft. Now, turn the adjusting screw clockwise

cylinder.

until the backlash is just eliminated.

3. Using the tool R O 1016 and spring balance,

measure and record the maximum rolling
resistance at the input shaft.

4.

Fit a new locknut to the adjuster screw but do
not tighten. Continue to rotate the input shaft,
with the spring balance, whilst turning the
adjuster screw until the figure recorded

in

instruction 3 is increased by 0,9 to 1,3 kg.

Tighten the locknut and check the above
figures again.

5.

Turn

the rack adjuster clockwise to impart

Pressure upon the rack and back-off half a
turn. Again, using special tool R O 1016 and
the spring balance, rotate the input shaft

whilst turning the rack adjuster until the figure

recorded in instruction 4

is

increased by a

te that the final rolling

resistance figure, recorded

on

the spring

3.

Now, compress the ring by hand, whilst

feeding the ring into the groove by striking it
with a hammer until the ring finally springs

into position

in

the groove. Ensure that the

ring is fully seated by tapping it round with a
punch.

6. When satisfied that the pre-load figures are

satisfactory, lock the rack adjuster in position
with the grub screw.

REISSUED:

FEB

1993

19

further 0,9 to 1,3 kg. No

balance, must not exceed 7,25 kg.

Рассказать друзьям