Defender (1999-2002). Manual — part 86
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60
FRONT SUSPENSION
2
REPAIR
12. Knock back staking and using a suitable socket,
remove and discard hub nut.
13. Remove washer from hub.
14. Remove hub and brake disc assembly complete
with bearings.
15. Remove outer bearing and spacer from hub.
16. Remove grease seal and inner bearing from
hub.
17. Remove inner and outer bearing tracks from
hub.
Refit
18. Clean hub and bearing locations.
19. Fit inner and outer bearing tracks to hub.
20. Pack inner bearing with grease and fit to hub.
21. Fit new seal flush with rear face of hub using
LRT-54-003 and LRT-99-003.
22. Clean stub axle.
23. Pack outer bearing with grease, fit spacer and
bearing to hub.
24. Position LRT-54-019 over hub nut threads on
axle casing.
25. Fit hub assembly to stub axle, remove
LRT-54-019.
26. Fit washer and new hub nut and tighten to 30
Nm (22 lbf.ft).
27. Rotate and push/pull hub to setle bearings.
Tighten hub nut to 210 Nm (150 lbf.ft).
28. To check drive shaft end float, mount a dial
gauge using bracket LRT-99-503 to driving
member bolt hole.
29. Ensure dial gauge is contacting hub nut face.
30. Move drive shaft in and out noting dial gauge
reading.
31. If end float is present refer to table for correct
spacer and change spacer as necessary.
32. When no end float is evident, remove the dial
gauge and mounting bracket.
33. Stake the hub nut.
34. Clean hub and axle shaft faces.
35. Fit new driving member gasket.
36. Position driving member to hub and tighten new
bolts to 65 Nm (48 lbf.ft).
37. Fit original shim(s) to drive shaft and secure with
circlip.
38. Position brake caliper to hub, align fixings, fit
bolts and tighten to 82 Nm (60 lbf.ft).
39. Remove plugs from brake pipe connections.
40. Connect brake pipe union to jump hose and
tighten union.
CAUTION: Use 2 spanners when
tightening or loosening unions.
41. Remove brake hose clamp from jump hose.
42. Bleed brake system. See BRAKES,
Adjustment.
43. Fit road wheel, remove axle stand and tighten
wheel nuts to 130 Nm (95 lbf.ft).
44. Operate foot brake to locate brake pads before
taking vehicle on road.
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FRONT SUSPENSION
3
REPAIR
End Float (mm)
Spacer size
(mm)
Colour code
0.00
15.5
Purple
0.025
15.4
Yellow
0.050
15.4
Yellow
0.075
15.4
Yellow
0.10
15.3
Red
0.125
15.3
Red
0.150
15.3
Red
0.175
15.2
Blue
0.200
15.2
Blue
0.225
15.2
Blue
0.250
15.2
Blue
0.275
15.1
Green
0.300
15.1
Green
0.325
15.1
Green
0.350
15.1
Green
0.375
15.0
Black
0.400
15.0
Black
0.425
15.0
Black
0.450
15.0
Black
0.475
14.9
White
0.500
14.9
White
0.525
14.9
White
0.550
14.9
White
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REAR SUSPENSION
1
REPAIR
BEARING - REAR HUB
Service repair no - 64.15.14
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove rear road wheel.
3. Remove 2 bolts securing brake caliper to hub.
4. Release caliper from disc and tie aside.
5. Remove 5 bolts securing axle shaft.
6. Remove axle shaft and discard gasket.
7. Knock back staking, and using a suitable socket,
remove and discard stake nut.
8. Remove hub nut washer.
9. Remove hub and brake disc assembly complete
with bearings.
10. Remove outer bearing and spacer from hub.
11. Remove grease seal and inner bearing from
hub.
12. Remove inner and outer bearing tracks from
hub.
Refit
13. Clean hub and bearing locations.
14. Fit inner and outer bearing tracks to hub.
15. Pack inner bearing with grease and fit to hub.
16. Fit new grease seal flush with rear face of hub
using LRT-54-003 and LRT-99-003.
17. Clean stub axle.
18. Pack outer bearing with grease, fit spacer and
bearing to hub.
19. Fit hub assembly to stub axle, remove
LRT-54-019.
20. Fit washer and new hub nut and tighten to 30
Nm (22 lbf.ft).
21. Rotate and push/pull hub to settle bearings.
Tighten hub nut to 210 Nm (150 lbf.ft).
22. To check drive shaft end float, mount a dial
gauge using bracket LRT-99-503 to driving
member bolt hole.
23. Ensure dial gauge is contacting hub nut face.
24. Move drive shaft in and out noting dial gauge
reading.
64
REAR SUSPENSION
2
REPAIR
25. If end float is present refer to table for correct
spacer and change spacer as necessary.
26. When no end float is evident, remove the dial
gauge and mounting bracket.
27. Stake the hub nut.
28. Clean hub and axle shaft faces.
29. Fit new driving member gasket.
30. Position driving member to hub and tighten new
bolts to 65 Nm (48 lbf.ft).
31. Fit original shim(s) to drive shaft and secure with
circlip.
32. Position caliper to hub, fit bolts and tighten to 82
Nm (61 lbf.ft).
33. Fit road wheel, remove axle stands and tighten
road wheel nuts to 130 Nm (96 lbf.ft).
34. Operate brake pedal to locate brake pads before
driving vehicle.
35. Check and top up brake fluid.
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