Content .. 103 104 105 106 ..

Defender 90 / 110 / 130. Manual - part 105

STEERING

Fitting the valve and worm assembly

62.

removed, refit the original shim

and

the inner bearing cap. Only vaseline must be used
as an aid to assembling the bearings.

NOTE: If the original shims are not available, fit

of 0.76

(0.030 in) nominal thickness.

63.

Fit

the inner cage and bearings assembly.

64. Fit the valve and worm assembly, using seal saver

to protect the input shaft seal.

65.

Fit the outer cage and bearings assembly.

66.

Fit the outer bearing cup.

Fitting the rack and piston

71. Screw a suitable bolt into the piston head for use as

an assembly tool.

72. Fit the piston and

assembly

so that the piston

is 63.5

(2.5 in) approximately from t h e outer

end

of the bore.

73. Feed in the sector shaft using seal saver 606604

aligning the centre gear pitch on the rack with the
centre gear tooth on

t h e

sector shaft. Push

sector shaft, and, at the same time rotate the input
shaft about a small arc to allow the sector roller to
engage the worm.

continued

67.

Renew the worm adjuster sealing ring and loosely

screw the adjuster into the casing. Fit the locknut,
but do not tighten.

68. Turn in the worm adjuster until the end-float at the

input is almost eliminated.

69. Measure and record the maximum rolling distance

of the valve and worm assembly, using a spring
balance and cord coiled around the torque setting
tool

adjuster

increase the figure

recorded in instruction 69 by

1,8 to

2,2

5 Ib) at 1.250 in (31.7

radius to settle the

bearings, then back

off

the worm adjuster until the

figure recorded in instruction 69 is increased by

0,9

to 1,3

3 Ib) only, with the locknut tight.

Use peg spanner 606601 and

'C'

spanner 606600.

STEERING

Fitting the rack adjuster

74.

Fit the sealing ring to the rack adjuster.

75. Fit the rack adjuster and thrust pad to engage the

76. Loosely fit the nylon pad and adjuster grub screw

Fitting the cylinder cover

82. Fit the square section seal to the cover.
83. Remove the slave bolt and press the cover into the

cylinder just sufficient to clear the retainer ring
groove.

84. Fit the retainer ring to the groove with one end

the ring positioned 12

(0.5 in) approximately

from the extractor hole.

rack. Back off a half turn

on t h e adjuster.

assembly to engage the rack adjuster.

Fitting the sector shaft cover

Fit the sealing ring to

cover.

78. Screw the cover assembly fully on to the sector

79. Position

cover on to the casing.

80. Tap home the cover. If necessary back off

sector shaft adjuster screw to allow the cover to

joint fully with the casing.

shaft adjuster screw.

NOTE: Before tightening the fixings, rotate the
input shaft about

a small arc to ensure that the

sector roller is free

move in the valve worm.

81. Fit t h e cover fixings and torque load to 2,2 to 2,8

kgf

(16 to

Ibf ft) (23 to

28 Nm).

Adjusting the sector shaft

85. Set the worm o n centre by rotating the input shaft

half the total number of turns from either lock.

86.

Rotate the sector shaft adjusting screw anti-

clockwise to obtain backlash between

input

shaft and the sector shaft.

87. Rotate the sector shaft adjusting screw clockwise

until the backlash

is just eliminated.

88. Measure and record the maximum

rolling

resistance at the input shaft,

using a spring balance,

cord and torque tool

89. Hold still the sector shaft adjuster screw and

loosely fit a new locknut.

90.

Turn

the sector shaft adjuster screw until the

figure

in instruction

88 is increased by

to 1,3

(2 to

3 Ib) with the locknut tightened.

continued

STEERING

Adjusting the rack adjuster

91.

Turn

the rack adjuster to increase the figure

recorded

90 by

0,9

1,3

(2 to 3 lb). The final

figure may be less than but must not exceed

(16

Ib).

92.

Lock the rack adjuster in position with the grub
screw.

Adjustments

95.

Note where the greatest figures are recorded
relative to the steering gear position. If the greatest

figures are not recorded across the centre

of travel

(i.e. steering straight ahead position), adjust as
follows:

L.H. steering models. If the torque peak occurs

before  the  centre  position,  add  to  the  shim
washer valve; if  the torque peak  occurs after
the  centre  position,  subtract  from  the  shim
washer valve.

R.H. steering models. If the torque peak occurs

before the centre position, subtract from the

shim washer valve; if the torque occurs after
the centre position, add to the shim washer
valve.

Shim washers are available as follows:

and

(0.0015 in,

0.003 in, 0.005 in and 0.010 in).

Torque peak check

With  the  input  shaft  rotated  from  lock-to-lock,  the
rolling  resistance  torque  figures  should  be  greatest
across  the  centre  position

turns approximately

from full lock) and equally disposed about the centre

position.

This condition depends on the value

of shimming fitted

between

the valve and worm assembly inner bearing

cup and the casing.

The original shim washer value will

give the correct torque peak position unless major
components have been replaced.

NOTE: During the following 'Procedure', the stated
positioning and direction

of the input shaft applies for

both

L.H. and R.H. boxes. However, the procedure for

shim adjustment where necessary,  differs between L.H.
and  R.H.  steering  boxes  and  is  described  under  the
applicable L.H.  stg. and R.H.  stg. headings.

Procedure

93. With the input coupling shaft toward the operator,

turn

the

shaft fully anti-clockwise.

94. Check the torque figures obtained from lock-to-

lock using a spring balance cord and torque tool

NOTE: Adjustment

(0.003 in) to the shim

value

move the torque peak area

.by

turn

approximately on the shaft.

96. Fit the drop arm to the steering box

using a new

tab

washer. Tighten the nut to the correct torque and
bend over tab.

97. Refit the steering box to the vehicle.
98. Replenish the system with the correct grade of

fluid. Refer to Recommended Lubricants and
bleed the system.

99.

Test the system for leaks, with the engine running,
by holding the steering hard on full lock in both

directions.

NOTE:

Do not maintain this pressure for more than

seconds in any one minute to avoid over-heating

the fluid and possibly damaging the seals.

Road test the vehicle.

STEERING

BLEEDING THE POWER STEERING SYSTEM

TEST POWER STEERING SYSTEM

Service tools:
Three-way adaptor
Gauge

Hose

JD 10-3

2-off Hose

JDIO-3A

Adaptor

If there is a lack of  power assistance for the steering the
pressure of  the hydraulic pump should be checked first
before  renewing  any  components

of the system. The

fault diagnosis chart should also be used to assist in
tracing faults in the power steering.

PROCEDURE

1. The hydraulic pressure test gauge is used in

conjunction with the special adaptor (as illustrated)
for testing the power steering system. This gauge is
calibrated to read up to

140

(2000

in the power steering system is

(850

2. Under certain fault conditions of the hydraulic

pump it is possible to obtain pressures up to

105

(1500

Therefore,

important  to  realise  that  the  pressure  upon  the
gauge  is in  direct proportion  to the pressure  being
exerted  upon  the  steering  wheel.  When  testing,
apply pressure to

t h e

steering wheel very gradually

while carefully observing the pressure gauge.

3 . Check, and if necessary replenish, the fluid

reservoir.

4. Examine the power steering units and connections

for leaks. All leaks must be rectified before
attempting to test the system.

5 .

Check the steering pump drive belt for condition
and tension, rectify as neccssary.

The pump used

on the

engined vehicle is

different  from  that  fitted  to  the  four  cylinder
engined  vehicles  but  the  test  figures  are  the  same
for  both  pumps,  Diagrams  show  how  t h e   test
equipment is assembled for both vehicles.

Assemble the test equipment in accordance with
the diagram for the vehicle concerned.

Open the tap in the adaptor

Bleed the system but exercise extreme care when

carrying out this operation so as not to overload the
pressure gauge.

With the system in good condition, the pressures
should be as

follows:

(a) Steering wheel held hard

on full lock and

engine running at

1,000

the pressure

(b)

With the engine idling and the steering wheel
held hard on full lock, the pressure should be

(400

minimum.

and the normal pressure which may be expected

continued

1. Fill the steering fluid reservoir to the mark

the

side

of the reservoir with

one

of the recommended

fluids.

2. Start and run the engine until it attains normal

operating temperature.

Run the engine at idle speed.

NOTE:

During the carrying out of items 4,

and 6,

ensure that the steering reservoir

is kept full. Do not

increase the engine speed

or move the steering wheel.

Slacken the bleed screw. When fluid seepage past

the bleed screw is observed, retighten the screw.

5 .

Ensure that the fluid level

is in alignment with the

Wipe

off all fluid released during bleeding.

Check all hose joints, pump and steering box for

fluid leaks under pressure by holding the steering
hard

o n full lock in both directions.

mark on the reservoir dipstick.

CAUTION: Do not maintain this pressure for more
than 30 seconds in any one minute, to avoid causing
the oil to overheat and possible damage to the seals.

The steering should be smooth lock-to-lock in both
directions, that is,

heavy

or light spots when

changing direction when the vehicle is stationary.

8. Carry out

a short road test. If necessary, repeat the

complete foregoing procedure.

Content .. 103 104 105 106 ..