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.