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.