Land Rover Defender Workshop 1993 Rover Manual
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STEERING 41. Fit the pedal box and secure with the six bolts. Fit the pedal assembly mill board trim and secure with retaining strip, vent cover and screws. 42. Fit the master cylinder to the servo and connect the servo vacuum hose. 43. Connect the stop lamp switch leads. Fitting steering column 34. Fit the main support bracket and padding to the steering column and manoeuvre the column into position in the vehicle. 35. Loosely secure the main support bracket and harness bracket to the bulkhead with two bolts. 36. Loosely fit the clamp and rubber packing strip to the column and retain with two bolts. 37. Loosely secure the lower end of the column to the lower support bracket with two nuts and bolts. 38. Loosely secure the clamp bracket to the main support bracket with two bolts. Fit steering column lock switch 44. Place lock switch in position and rotate the steering column inner shaft to line up the slot with the switch plunger. 39. Working inside the vehicle cab, fit the tie-bar to the column bracket and secure with the single bolt. 40. Finally tighten the main support bracket bolts, clamp bracket bolts, upper clamp bolts and the lower support bracket nuts and bolts. 4 REISSUED: FEB 1993
STEERING 45. Secure the lock to the column with the clamp and shear bolts, whilst inserting two plain washers between the switch and clamp. 47. Offer up the instrument panel and connect the Tighten the bolts but not enough to shear speedometer cable, two block connectors one them. Temporarily fit the steering wheel and multi-plug and single white wire. Secure the operate the switch and lock mechanism panel with the four screws. several times to ensure it functions properly before finally tightening the bolts until the heads shear. Connect the electrical leads to the rear of the switch Fit instrument panel and nacelle 48. Locate the top half of the nacelle in position. Locate the switch grommets and secure the two halves together with the four long screws one short and two self-tapping screws. Fit steering column switch assembly 46. Fit the steering column switch assembly and secure with the single screw. Connect the four multi -plugs to the main harness. Fit the steering wheel 49. Turn the cancelling ring so that the slots are vertical and the lug with the arrow points to the left, in the direction of the indicator switch. Engage the steering lock. 50. Fit the steering wheel with the finisher attachment lug at the bottom. Ensure that the indicator cancelling forks locate in the cancelling ring slots. Secure the wheel with the shake -proof washer and nut and tighten to the correct torque. Fit the finisher and secure with the single screw. REISSUED: FEB 1993 5
STEERING Fit collapsible steering shaft 51. If necessary, fit new universal joints to the support. Note that the long joint is fitted to the short length of shaft and short joint to the long end. The joints can only be fitted one way to the shaft. 52. With the steering lock engaged and the road wheels in the straight ahead position line -up the marks made in instruction 2 and fit the collapsible shaft assembly with the long leg of the shaft to the steering box. Fit the pinch bolts and tighten to the correct torque figure 22 - 28 Nm. TORQUE FIGURES Nm Drop arm nut ........................................................................\ ............................................................. 176 Steering wheel nut ........................................................................\ .......................... 38 Sector shaft cover to steering box ........................................................................\ .............................. 22 Top cover bolts ........................................................................\ ........................................................... 50 Top cover bolts from serial No: lJ0001 ........................................................................\ ........................ 75 6 REISSUED: FEB 1993
STEERING POWER STEERING BOX OVERHAUL Adwest Lightweight Special service tools Drop arm extractor C spanner Worm adjusting socket Ring expander Ring compressor Torque setting tool Seal saver, sector shaft MS 252A / LRT-57-012 LST 120 / LRT-57-007 LST 119 / LRT-57-006 RO 606602 / LRT-57-019 RO 606603 / LRT-57-020 RO 1016 / LRT-57-017 RO 606604 / LRT-57-021 Seal saver, valve and worm RO 1015 / LRT-57-016 7 REISSUED: FEB 1993
STEERING Dismantle 5. Slacken the grub screw locking the rack pad bring the steering to the straight ahead 6. Remove the rack pad adjuster clockwise and position and mark the relationship of the drop withdraw the pad. arm to the casing. Using special service tool 7. Remove the sector shaft lock nut. The nut, MS 252A withdraw the drop arm and remove which has a seal moulded inside it, also acts the outer dust seal. as a fluid seal. The nut should therefore be discarded and a replacement new nut obtained for reassembly. 8. Remove the sector shaft cover bolts. 9. Turn the sector shaft adjuster clockwise with a 6 mm Allen key whilst holding the cover, to prevent it turning, until the cover is removed. 10. The sector shaft can now be removed from the casing. 1. To assist assembly, turn the input shaft to adjuster. 2. Rotate the piston cover retaining ring until one end is about 12 mm from the extractor hole in the side of the cylinder housing. 3. Lever the retaining ring from its locating groove by inserting a suitable pointed drift through the extractor hole. Complete the removal of the ring using a screw driver. 4. To remove the cover, turn the input shaft, in the appropriate direction, until the piston pushes out the cover. For a left -hand steering box, position the sector shaft on the left -hand lock and for a right -hand box on the right -hand lock. 10 REISSUED: FEB 1993
11. To remove the piston, screw a suitable bolt into the piston crown and use it to pull the piston from the casing. STEERING 12. Remove the worm shaft adjuster lock nut using special service tool LST 120. 15. Remove the circlip from the sector shaft bore to enable the seal assembly to be withdrawn. 16. Similarly, remove the circlip from the input shaft (worm shaft) bore and remove and discard the seals. 13. Using service tool LST 119 remove the worm shaft adjuster. 14. To withdraw the shaft and bearings tap the splined end of the shaft and lift-out the assembly. REISSUED: FEB 1993 11
STEERING NOTE: The steering box has now been 2. Check the condition of the adjuster thread and dismantled except for the sector shaft bushes, that there is no excessive vertical play. A shown dotted. Since replacement bushes are not movement of 2 mm IS acceptable. Side play, available, they should not be removed. The input however, is of no significance. shaft inner bearing cup and shims may also still 3. Examine the bearing surfaces of the shaft for be in position if jarring of the box has not wear, scores and pitting. already dislodged them and instructions for 4. Check the gear teeth for excessive or uneven removing these appear later. wear, scores and pitting. 5. Examine the cover for damage and burrs. INSPECTION Remove and discard the seal. Check the bush for wear and scores. Also check the adjuster Steering box casing 6. Check the bleed nipple and threads and that the bleed whole in the inside of the cover is 1. Examine the piston bore for wear, scores and pitting. 2. Examine the inlet pipe thread in the side of the cylinder tube for damage and if necessary NOTE: For replacement purposes, the cover, repair using a suitable tap. bush and seal are supplied as a complete cracks and dents and renew if in any way faulty. 7. The locknut, which should be discarded, also 4. Since it is very unusual for the sector shaft acts as a fluid seal and a new one should be bushes to wear they are not available as fitted on assembly. replacements. However, they should nevertheless be checked for damage. 3. Check the feed pipe for damage especially for assembly. Sector shaft and cover assembly 1. Check that there is no side play on the roller. If excessive play does exist the sector shaft should be renewed likewise if any of the following checks are unsatisfactory. 12 REISSUED: FEB 1993 thread for damage clear.
STEERING Valve and worm assembly 1. Examine the bearing areas for wear. The surfaces must be smooth and free from indentations, scores and pitting. 2. Examine the worm for wear which must also be smooth and free of scores and indentations. 3. Check for any wear on the torsion bar assembly pins. Grip the splined end of the input shaft in a soft jawed vice and by hand twist the worm end. No free movement should exist between the input shaft and worm. NOTE: If any wear does appear in the above areas it is essential that a new valve and worm assembly is fitted. 6. Remove the expander tool and slide the compressor tool RO 606603 over the rings, internal chamfered end leading and leave until cool. 4. Examine the valve rings which must be free from cuts, scratches and grooves. The valve rings must be a loose fit in the valve grooves. If any one of the rings is faulty, all the rings must be renewed. Take care not to damage the ring grooves when removing the rings. 5. Fit replacement rings using expander tool RO 606602. Expand the rings by immersing them in hot water until pliable then carefully slide the rings over the tool, from the chamfered end. Place the tool over the ring grooves and slide the first ring into the groove nearest to the worm and so on until the third ring is in place. It is important to fit the rings in this sequence since the tool will not pass over the rings. REISSUED: FEB 1993 13