Defender 300Tdi (1996+). Manual — part 67
64
REAR SUSPENSION
2
REPAIR
BUMP STOP
Service repair no - 64.30.15.
Remove
1. Remove fixings.
2. Remove bump stop.
Refit
3. Position bolts in slots in bracket.
4. Fit bump stop, secure with washers and nuts.
SUSPENSION LINK - UPPER
Service repair no - 64.35.44.
Remove
1. Support rear of chassis on stands, allow axle to
hang freely.
2. Remove fixings, upper link bracket to frame.
3. Remove fixings, upper links to pivot bracket.
4. Remove upper link, complete with frame bracket.
5. Remove bolt.
6. Separate link from bracket.
Renew bush
7. Press out rubber bushes.
8. Fit bush centrally in housing.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
REAR SUSPENSION
3
REPAIR
Refit
NOTE: Do no fully tighten fixings until all
components are in position.
9. Secure link to frame bracket.
10. Fit upper link to pivot bracket.
11. Fit frame bracket to chassis mounting.
12. Fully tighten fixings to
176 Nm (130 lbf/ft).
SUSPENSION LINK - LOWER
Service repair no - 64.35.02.
Remove
1. Site vehicle on a ramp .
2. Alternatively, support vehicle on stands under
rear axle.
3. Remove lower link rear fixings.
4. Remove mounting bracket fixings at side
member bracket.
5. Remove lower link complete.
6. Remove locknut.
7. Remove mounting bracket from lower link.
Renew bush
8. Press out rubber bushes.
9. Fit bush centrally in housing.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
Refit
10. Fit mounting rubber to lowerlink.
11. Secure mounting rubber to chassis bracket, but
do not fully tighten locknut.
12. Fit lower link to axle mounting and secure fixing
to
176 Nm (130 lbf/ft).
13. Lower vehicle, allow axle to take up static laden
position, and fully tighten link chassis fixing to
176 Nm (130 lbf/ft).
64
REAR SUSPENSION
4
REPAIR
ANTI-ROLL BAR
Service repair no - 64.35.08
Remove
1. Note for reassembly, position of rubber bushes
on anti-roll bar.
2. Remove 4 nuts, bolts and washers securing both
anti-roll bar bush straps to chassis mounting
brackets.
3. Remove nuts, bolts, washers and rubber bushes
securing anti-roll bar to links.
4. Remove anti-roll bar.
Refit
5. Position rubber bushes on anti-roll bar. Fit joint
towards axle.
6. Fit anti-roll bar with two straps. Ensure link arms
point down as shown. Loosely fit, bolts, washers
and new nyloc nuts.
7. Fit bolt, washers and rubber bushes. Fit anti-roll
bar to links and tighten to
68Nm (50 lbf/ft).
8. Tighten nuts securing straps to
30Nm (22 lbf/ft).
REAR SUSPENSION
5
REPAIR
ANTI-ROLL BAR LINKS
Service repair no - 64.35.24.
Remove
1. Remove 2 nuts, bolts, washers and rubber
bushes from links and lower anti-roll bar to clear
links.
2. Remove cotter pin and loosen castellated nut a
few turns.
3. Release link using special tool 18G 1063A as
shown.
4. Remove castellated nut and remove link.
Refit
5. Fit anti-roll bar link arm and castellated nut. Point
link arm down as shown. Tighten fixing to
40 Nm
(30 lbf/ft) and fit new cotter pin.
6. Align anti-roll bar to links.
7. Fit bolts, washers and rubber bushes using new
self locking nuts and secure anti-roll bar to links.
Tighten to
68Nm (50 lbf/ft).
SELF LEVELLING UNIT
Service repair no - 64.30.09
Remove
WARNING: The levelling unit contains
pressurised gas and MUST NOT be
dismantled. Repair is by replacement of
complete unit only.
1. Raise and support the vehicle under chassis and
use a jack to support weight of the axle.
2. Disconnect upper links at pivot bracket.
3. Ease up levelling unit lower gaiter and unscrew
lower ball joint at push rod using thin jawed
spanners.
4. Release webbing strap from the chassis.
5. Remove 4 nuts securing top bracket to chassis
and withdraw levelling unit complete with
bracket.
Renew levelling unit ball joints
The ball joints for the levelling unit may be dismantled
for cleaning and examination.
6. Unscrew lower ball joint from pivot bracket.
7. Unscrew ball joint from top bracket.
8. Reassemble ball joints, packing with
Dextagrease G.P. or equivalent. Renew joints if
worn.
9. Check condition of gaiters and renew if
necessary.
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