Defender (1993+). Instruction - page 78

STEERING

TRACK ROD AND DRAGLINK

When adjusting

or

renewing a track rod or draglink it

is important to ensure that the ball joints are
assembled in the same angular plane and that the
ball joint pins are central in their respective housings,

as example

'A'

illustrated below. Premature wear

could result if the pins are inclined to one-side as
illustration 'B'.

4.

Check the alignment as advised by the
equipment supplier.

Adjusting

CAUTION: A track rod or draglink that is

5. Slacken the clamps at both ends

of

the track

damaged or bent must be renewed.

No attempt

rod.

should be made to repair

or straighten it.

6. Turn the track rod

to

increase or decrease its

effective length until the toe-out is correct.

FRONT WHEEL ALIGNMENT - Check and adjust

7. Push the vehicle rearwards turning the

steering wheel from side to side to settle the

Checking

ball joints. Then, with the road wheels in the
straight ahead position, push the vehicle

NOTE:

Recognised

front

wheel

alignment

forward a short distance.

tracking equipment should be used to perform

8. Re-check the track and if required, adjust as

this operation. Only the use of basic equipment

necessary.

is described below.

See

section 04

for

alignment

9. When the alignment is correct, tap the ball

data.

joints

in

direction of the arrows

to

the

Make the following checks before commencing:

maximum of their travel

to

ensure full

The vehicle

is

on level ground.

unrestricted movement of the track rod. Then

The vehicle is not loaded.

return the joints to a central position and in

The wheels run true and are not damaged or

line.

buckled.

The track rod is not damaged or bent.
The ball joints are not

worn and boots are not

split.
The joints are Set in the same angular plane and
central in their housings. See 'Track rod and drag
link'.

1.

Set the road wheels

in

the straight ahead

position and move the vehicle forward a short
distance for at least two revolutions of the
wheels.

2.

Set up the equipment to the manufacturers
instructions.

3.

Position the trammel probes on the inner face
of the wheel, not the rims, if the latter are
damaged.

10. Finally, tighten the ball joint clamp nuts and

bolts to the correct torque.

32

REISSUED:

FEB

1993

SUSPENSION

OVERHAUL REAR SUSPENSION

22. Using ball joint extractor tool R01006 or

a

suitable proprietary tool remove the ball joint

Remove the

lower links

from the axle bracket.

23. Remove the pivot bracket complete with the

ball joint and if fitted, the lower ball joint of the

24. Remove the two bolts securing the ball joint

to

the pivot bracket and press the ball joint from
the bracket.

1. Jack up the rear of the vehicle and lower on

2. Remove the nut and bolt retaining the lower

link to the axle bracket.

3. Remove the three nuts and bolts retaining the

foward end of the link to the chassis bracket.

4. Withdraw the lower link from the vehicle.

5.

Remove the locknut and washer and remove
the flexible mounting from the link.

to axle stands.

levelling unit.

NOTE: Replacement ball joints are supplied as
complete assemblies packed with grease.

25. Using

two

bolts as a guide to ensure correct

alignment press the knurled ball joint into the
pivot bracket and secure with the two nuts
and bolts.

Renew the bushes

6.

Press out the bush from the rear end of the
lower link.

7.

Press a new bush squarely into the link.

Assemble upper links and ball joints

Fit the lower link

26. Fit the pivot bracket ball joint and bracket

to

the axle and secure with the plain washer
castle nut and split pin. Tighten the nut to 176

Nm.

8. Assemble the flexible mounting

to

the link and

secure with the locknut but do not tighten at
this stage.

27. Fit the levelling unit, if used.

end of the link to the chassis bracket with the
three nuts and bolts.

10.

Assemble the rear end of the link to the axle
bracket and retain with the nut and bolt, but
do not tighten at this stage.

11. Lower the vehicle

to

the ground and allow the

suspension

to

settle.

12. Tighten the nut and bolt at the rear end

of

the

link.

13.

Tighten the forward locknut

to

176 Nm.

9. Fit the link to the vehicle, securing the front

28. Assemble the upper links to the chassis

attachment brackets but do not at this stage
fully tighten the pivot nut and bolt.

29. Fit the upper link assemblies to the chassis

with the six nuts and bolts, (three each side).

Note the positions

of

the bolt heads. Tighten

the nuts to 47 Nm.

30.

Secure the rear ends of the upper links

to

the

pivot bracket and tighten the two nuts and
bolts and tighten to 11

5

Nm.

31.

Remove the jack from the chassis, allow the

suspension to settle and tighten upper link

Remove upper links

pivot bolts.

14. Jack up the vehicle under the chassis

so

that

the rear axle is freely suspended.

15. Remove nuts and bolts retaining the upper

32. Remove the two nuts and bolts securing the

link bracket

to

the chassis frame.

anti-roll bar to the axle link.

16. Remove the

two

nuts and bolts securing the

33. Remove the eight nuts and bolts (four each

upper links

to

the pivot bracket.

side) retaining the anti-roll bar to the chassis

17. Withdraw the upper links complete with the

and remove the bar

from

the vehicle.

chassis attachment brackets from vehicle.

34. Remove the split pin and castle nut and

18. Remove the nut and bolt retaining forward end

remove the ball joint and link from the axle

of the link

to

the chassis bracket and separate

location.

the

two

parts.

If the ball joint requires replacement the

19. Press out the bush from the forward end of

complete link must be renewed.

the links and squarely press in new bushes.

35. Renew the rubbers and fit the anti-roll bar to

the chassis and secure with the eight bolts

and nuts tightening to 24 Nm.

36. Fit the ball joint and link

to

the axle location

20. Remove the levelling unit

-

if

fitted.

and tighten the castle nut to 40 Nrn and

fit

a

21. Remove the split pin, castle nut and plain

new split pin.

washer securing the ball joint to the pivot

37. Fit the anti-roll bar to the ball joint link and fit

bracket.

new bushes in the sequence illustrated and

tighten the nuts and bolts, to the correct

Renew anti-roll bar bushes and ball joints

Renew pivot bracket ball joint

SUSPENSION

LEVELLING UNIT

Functional check

A

Boge Hydromat levelling unit is located in the

centre

of

the rear axle.

When the vehicle is unladen the levelling unit has
little effect. The unit is self-energising and hence the
vehicle has

to

be driven before the unit becomes

effective, the time taken for this to happen being
dependant upon the vehicle load, the speed at which
it is driven and the roughness of the terrain being
crossed.

If the vehicle is overloaded the unit will fail to level

6. Load weights to the value

of

650 kg evenly

fully and more frequent bump stop contact will be

over the rear load area

of

the vehicle and

noticed.

leave it to settle undisturbed

for

minimum

Should the vehicle be left for a lengthy period e.g.

period of thirty minutes.

overnight, in a laden condition, it may settle. This is

7. With the driving seat occupied or with an

due to normal internal fluid movement in the unit and

approximate equivalent weight of 75 kg check

is not detrimental to the unit performance.

the bump stop clearance and note the

Before carrying out he checks below, verity that the

measurement.

vehicle is being operated within the specified

8. Drive

the

vehicle

on

a

test

route

maximum loading capabilities. If the levelling unit is

approximately

5

km in length over undulating

then believed to be at fault, the procedure below

roads or graded tracks. At the completion

of

should be followed.

the drive bring the vehicle to rest by light

Whilst slight oil seepage

is

permissible, the unit

brake application

so

as not to disturb the

should be renewed if there is an excessive oil leak.

vehicle loading.

9. Without disturbing the vehicle load and with

1.

Remove excessive

mud

deposits

from

the driving seat occupied, check the bump

underneath the vehicle and any heavy items

stop clearance and note the reading, which

from inside the vehicle that are not part

of

the

must be in excess of

45

mm (average).

original equipment.

10.

Subtract

the

reading

obtained

under

2.

Measure the clearance between the rear axle

Instruction 7 from that obtained under

bump pad and the bump stop rubber at the

Instruction 9. If the change in clearance is in

front outer corner on both sides of the vehicle,

excess

of

10

mm the levelling unit is

dimension

A.

The average clearance should

functioning correctly.

be

in

excess of 67 mm.

11.

If the figures obtained in instructions 9 and 10

3 . If the bump stop clearance is less than the

do not exceed 45 mm and

10

mm

respectively

above figure remove the rear springs and

unload the vehicle and renew the levelling

check the free length against the following

unit.

data

in

the chart.

4. Renew any spring where the

free

length is

more than

20

mm shorter than the figures

in

the chart.

5.

Having refitted or renewed any springs repeat
the clearance check as described above.

If

the average bump clearance

is

still less than

67 mm renew the levelling unit.

LAND ROVER COIL

SPRING

SPECIFICATION

PART

NO.

DESCRIPTION

COLOUR CODE

LOCATION

SPECIFICATION

FREE LENGTH

NRC 6388

Drivers

Blue Stripe

Rear

Suspension

420

mm

NRC 7000

Passengers

Green & White

Rear

Suspension

400

mm

Levelled

Levelled

Levelled

Stripes

Levelled

SUSPENSION

REMOVE LEVELLING UNIT

SPRINGS AND SHOCK ABSORBERS

WARNING:

The

levelling

unit

contains

Remove rear springs

pressurised gas and must not be dismantled nor

1.

Slacken the rear road wheel nuts and raise

the casing screws removed. Repair is by

the rear of the vehicle and lower the chassis

replacement

of

complete unit only.

on the axle stands or similar supports and
remove the road wheels.

1.

Raise and support the vehicle under the

2.

Support the weight of the axle with a jack.

3.

Disconnect the shock absorbers at the lower

chassis and use a jack to support the weight
of the axle.

end.

2.

Disconnect the upper links at the pivot

4. Remove the spring retainer plate.

bracket.

5.

Lower the axle sufficiently to withdraw the

3.

Ease up the levelling unit lower gaiter and

spring, but take care not

to

stretch the flexible

unscrew the lower ball joint at the push rod

brake hose by lowering the axle too far.

using thin jawed spanners.

6. Remove the spring pan.

4.

Release the webbing strap from the chassis.

5.

Remove the four nuts securing the top bracket

Fit rear springs

to

the chassis and withdraw the levelling unit

complete with bracket.

7.

Fit the spring pan and retainer plate.

8.

Fit the spring into the chassis top location and
using a turning motion fit the spring

to

the

Renew levelling unit ball joints

axle pan.

9. Secure the shock absorbers with the rubbers

The ball joints for the levelling unit may be

correctly located.

dismantled for cleaning and examination.

10. Remove the axle support, fit the road wheels

6. Unscrew the lower ball joint from the pivot

and lower the vehicle

to

ground.

bracket.

11.

Finally tighten the road wheel nuts.

7.

Unscrew the ball joint from the top bracket.

8.

Reassemble the ball joints, packing with

Remove shock absorbers

Dextagrease

G.P.

or

equivalent or

if

12.

Slacken the road wheel nuts, raise the rear

of

necessary renew the joints if worn.

the vehicle and support it under the axle and

9.

Check the condition

of

the gaiters and renew

remove the road wheels.

if necessary.

13. Remove the shock absorber upper and lower

retaining nuts and rubbers.

Fit levelling unit

14. Remove the shock absorber from the top

locating shaft and withdraw it from the vehicle.

10.

Ensure the ball pin threads are clean and

smear Loctite grade CVX on the ball pin

Test shock absorbers

threads.

15.

Hold the shock absorber vertically in a vice,

11.

Fit the upper ball joint to the levelling unit and
secure the gaiter.

16.

The shock absorber employs differential

12.

Fit

the top bracket complete with levelling unit

damping having greater resistance on the

to the chassis and secure with the four nuts

extension

stroke.

Check

operation

by

and tighten to 47 Nm.

extending

and

compressing the

shock

13. Fit the levelling unit

to

the

lower

ball joint and

absorber.

secure the gaiter.

Resistance should be uniform throughout the

14. Attach the webbing strap to the chassis cross

length of each stroke. If resistance is erratic

member.

or weak, renew the shock absorber. When

15.

Fit the upper links

to

the pivot bracket and

checking resistance a new shock absorber

retain with the

two

bolts

and nuts but do not

may be used for comparison.

To

ensure that

tighten at this stage.

the new shock absorber

I

S

primed, fully

16. Remove the jack in support of the axle and

extend and compress the unit several times

the support from under the chassis.

before testing begins.

17.

Allow the suspension to settle and then
tighten the

two

bolts and nuts retaining the

upper links to the pivot bracket to the correct

17.

Fit the shock absorbers using new rubbers

torque.

and fit the lower rubbers and caps

in

the

18.

Fit the road wheels, lower the vehicle and

being careful not

to

damage the threads.

Fit shock absorbers

order illustrated.

finally tighten the road wheel nuts.

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