Defender 90 / 110 / 130. Manual - part 102
STEERING
GEMMER
MANUAL
STEERING
BOX
OVERHAUL
Special tool:
RO 1016
Dismantle
1. Remove the steering box from the vehicle, and
2. Remove the adjuster locknut.
3. Remove the four bolts securing the top cover.
4. Unscrew the top cover from the adjuster.
5.
Lift out the sector shaft.
6.
Remove the four bolts securing the worm shaft
retaining plate and remove the plate complete with
shims and joint washer.
remove the drop arm.
7. Remove the taper bearing and track.
8. Withdraw the worm shaft and collect the opposite
taper bearing.
.9. Drift out the worm shaft oil seal.
10. Drift out the shaft-end bearing track and collect the
shim. Note since this shim or one of the same value
must be refitted, as a precaution against loss, check
the thickness with a micrometer and note the
reading.
11.
Prise out the sector shaft
oil seal.
12. Drift out the sector shaft needle roller bearings.
Inspection
13. Clean and degrease all parts and examine for wear
14. Renew the bearings (if worn), oil seals and joint
15.
If
the bearing
in the top cover is worn renew the
Assembling
Cleanliness, during the following instructions, is
essential.
16. Press o r drift in the worm, shaft-end,
track
ensuring that the same shim or one of the same
value
is fitted behind the track. It is essential that
the track is fitted squarely and pressed fully home.
17. Lubricate and
fit
the bearing to the shaft and insert
the shaft into the box.
18. Lubricate and fit the opposite bearing and track to
the worm.
19. Fit the cover plate, joint washer and original shims.
Secure with the four bolts and evenly tighten to 25
to
30
(18 to 22 Ibs ft).
20. Check the worm shaft bearing pre-load by
attaching special tool
or a similar
alternative
(2.5 in) diameter,
to the worm
shaft. Wrap string round
the tool and attach a
spring balance
to
one end and with a steady pull
note the rolling resistance which should be 2.26 to
2.72
( 5
to
6
Ibs force). Adjust by adding or
subtracting shims. When the correct figure is
achieved, remove the bolts, coat the threads with
sealant and
fit
and evenly tighten to within the
above torque figures.
and damage.
washers and any other unsatisfactory parts.
complete cover with bearing.
21. With the lip side leading
fit the oil seal to the
shaft-end of the box.
NOTE: When performing instructions 22, 23 and
26
pressure must
only be
applied to the hardened square
end
of the bearings.
22. Press in the sector shaft top bearing to a depth of
83
(3.150 in) from the top machined face o f
the steering box.
23. Press in the sector shaft lower bearing
(0.040 in) below the chamfer.
24. Check that
n o end-play exists in t h e sector shaft
adjuster.
To reduce end-play unstake the threaded
cup and turn clockwise until all play
is removed and
25.
Fit the sector shaft so that the roller is in the centre
of the worm
in
the straight ahead position.
26.
Fit the bearing to the sector shaft top cover.
27. Screw the top cover onto the adjuster and secure
with the four bolts and evenly tighten to 25
30
(18 to 22 Ibs ft).
28. Loosely fit the adjuster locknut.
29. Keeping the sector shaft
in
the
straight ahead
position fit the drop arm and turn the adjuster
clockwise until pre-load is applied to the shaft.
The
amount of pre-load should be such that when the
shaft is turned half a turn to the left then half a turn
to the right, the backlash must only just be
perceptible. When satisfactory tighten the adjuster
locknut.
30. Fit the sector shaft
oil seal.
31. Remove the oil filter plug and pour in
approximately
litres (0.75 pints) of the
appropriate recommended oil to a minimum level
of 25
(1.0 in) below the top of the filler hole.
Refit the plug and tighten to 20
(14.75 Ibs
ft).
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