UNCONTROLLED IF PRINTED 2. Associated Publications 110 4x4and6x6to assesswearin suspension andsteering components. 1. Introduction 4. 40% off-roadoperationarelistedinTable1. significantly increased wearrates requiring more frequent componentssuspension isdependant 3. Inspection Criteria As component wear accelerates, the overallstabilityofavehicl componentaccelerates, As wear ENGINEERING INSTRUCTIONS ELECTRICAL ANDMECHANICAL out anyactionrequiredbythisinstru mandatory controls andproceduresforthe operation, main Thisinstruction is authorised foruseby command ofthe Chief ofthe General Staff. It provides direction,

j. i. h. d. c. b. a. documents: following the of latestissue the may to Reference necessary be the Rover on Land steering the and suspension the of inspection the criteriafor the details instruction This Specifications areshown in Table 2. stability ofavehicleisredu The l. m. k. f. g. e. TRUCK, LIGHTWEIGHT,MC2,LANDROVER1104X4–ALLTYPES EMEI Vehicle G 203 EMEI Vehicle G197-14 EMEI Vehicle G197-13 EMEI Vehicle G103 EMEI Vehicle A298-2 EMEI Vehicle A291-5 EMEI Vehicle A291-1 EMEI Vehicle G 209 110 6x6–Medium GradeRepair; Technical Regulation ofArmy Materiel Manual 6x6 –Servicing Schedule; and EMEI Vehicle G 204-1 6x6 –Light GradeRepair; EMEI Vehicle G109 Land Rover 1104x4–Medium GradeRepair; EMEI Vehicle G189-11 Land Rover 1104x4–Servicing Schedule; EMEI Vehicle G104-1 Land Rover 1104x4–Light GradeRepair; EQUIPMENT INSPECTIONANDEXAMINATIONDATA operated overharshterrain. inspectionThe intervals listed in Table 1should bereducedwhenavehicle is SUSPENSION ANDSTEERING TRUCK, LIGHT,MC2,LANDROVER1106X6 –Truck,Cargo, Light AndTruck,Cargo, Light, Mc2 Winch, -LandRover 110 –Truck,Cargo, Light AndTruck,Cargo, Light, Mc2 Winch, -LandRover 110

– Truck, Utility, Lightweight And Truck, Utility, Lightweight, Winch, Mc2 - Utility, Truck, Winch, Lightweight, And Utility,Lightweight Truck, – Mc2 - Utility, Truck, Winch, Lightweight, And Utility,Lightweight Truck, – ction inaccordancewithGENERALA001. – Tyres and Tubes – Inspection for Useability; Useability; for Inspection – Tubes Tyresand – –Tyres andTubes–General Service B Vehicle Tyre Guide; –Tyres andTubes–Care andMaintenance ofB Vehicles; – Truck, Utility, Lightweight And Truck, Utility, Lightweight, Winch, Mc2 - Utility, Truck, Winch, Lightweight, And Utility,Lightweight Truck, – –Truck,Cargo, Light AndTruck,Cargo, Light, Mc2 Winch, -LandRover –Repair ofManual Steering Box Sector Shaft EndFloat; and Retainers; Spring Coil of Fitting – –Reclamation ofPanhard Rod, Rear LowerLink andRadius Arm Mounts; on vehicleuse.Vehiclespredomin ced whenthesteeringandsuspensi NOTE inspection. Inspection intervals basedon60% on-road and

tenance andsupport ofequipment. Personnel areto carry INSPECTION PROCEDURE

(TRAMM). (TRAMM). e willdeterioraterapidly.Th on components arewornbeyondlimits. antly usedoff-roadwillexperience

e wearrateofsteeringand VEHICLE G188-1 Issue 2,Aug09 1

UNCONTROLLED IF PRINTED Issue 2,Aug09 VEHICLE G188-1 2 Serial Key 0 teigbxmutn ot 80N.m(60lbf.ft) Steeringboxsectorshaftendfloatmaximumallowable wear (tobesetatzeroduring 15 Steering shaftuniversaljoin 14 Toe Steering13 stopadjustment(tyreout wall toradi Droparmballjoint,draglink balljoint12 Steeringboxmountingbolts11 10 Serial La pigrce empvtbl 366N.m(270lbf.ft) 1.0mm(0.040in) 176N.m(130lbf.ft) 115N.m(85lbf.ft) 176N.m(130lbf.ft) 176N.m(130lbf.ft) Leafspringrockerbeampivotbolt 9 Leafspringsshacklebolts Toplinkballjointfreeplay 8 Toplinkballjointtoaxle 7 Rearaxletoplinktobody 6 5 Rearaxlelower linktoaxle 4 Swivel pinhousingbushwear limit Radiusarmmountings 3 Panhardrodmounting bolts 2 1 9 teigSo dutet I I I I I I I I,Y I I I I I,A I I I I I I I I I I I I I SteeringStopAdjustment Tyre Inflation,wear andtype 19 Steeringdamperandmountings 18 Trackrodandballjoints 17 I Draglinkandballjoints 16 I Droparmballjoint 15 Steeringboxmounts 14 Steeringboxendfloatandbacklash 13 Frontandrearbumprubbers 12 11 Frontandrearshockabsorbers 10 La pigrce em I I I I I I I I,A I I I I I I I I I I I I I Leafspringrockerbeam I Leafsprings,U-boltsandmountings 9 Frontandrearcoilsprings/seats I 8 I Top linkballjoint 7 Rearaxletoplinkandmountings I 6 Rearaxlelower linkandmountings 5 4 Swivel pinpousi Radiusarmandmountings 3 Panhardrodandmountings 2 1 :

A

–Adjust, adjustment) Leaf springU-bolts Rear axle lower link tochassis Swivel pinhousingbushpreload mountings bearings I –Inspect, Designation ng bushes,pinsand Y –Tighten

ic ot 20–25N.m(15–18lbf.ft) t pinchbolts Table 1InspectionIntervals Designation n rc o aljit 40N.m(30 lbf.ft) and trackrodballjoint Table 2Specifications sammnmmcerne 20mm (0.78in) us armminimumclearance) Safety Critical Item Check

I I I I

Repair inWorkshop Inspection After ELECTRICAL ANDMECHANICAL ENGINEERING INSTRUCTIONS

Major orAlt MajorServicing 1.2–2.4 mm(0.047–0.094in) 0.5 mm(0.02in) 128–142 N.m(95–105lbf.ft) 80–95 N.m(60–70lbf.ft) 176 N.m(130lbf.ft) 168–186 N.m(124–137lbf.ft) 4.5–9 kg(10–20lb) 0.4 mm(0.016in) Inspection DuringMinor, Specification

UNCONTROLLED IF PRINTED The vehicle should beroadtested after the inspection to identify orconfirm any handling problems or noises. inWear 7. 6. allow for elasticity of the bushes. bushes. the elasticityof for allow manufactured at unit level (Figure 1).Alternatively, atyre lever canbemodified. testing When for bush movement, referred to throughout the inspection procedures,is 5. Inspection Guidelines ENGINEERING INSTRUCTIONS ELECTRICAL ANDMECHANICAL The inspectorshouldconsider when th Before commencing the inspection, ensurethat the vehicle is onlevel groundwith the parkbrakeapplied. The inspection proceduresforsteering andsuspension are Modified levers arenot to beusedfortyre changing. or stamped onthe tool. The words‘LANDROVERSUSPENSIONINSPECTIONLEVER’areto be engraved swivel pinwear. mm. 20 lever of the to awidth willallow be to for This used checking bend sharp manufacture the inspection lever, modify the tyre lever by grinding the end with the This figure showsarepresentation ofaHeyco 1500brandtyre lever. To Funding isaunitresponsibility. bolts andmounting brackets with wornbushes. or shapeafter contraction, dilation ordistortion. Donot confuseworn mounting willresume bulk itsnormal mounting or abush meansthat definition, by Elasticity, Two personsarerequired to complete some ofthe inspection procedures. Figure 1Manufactureof LandRover SuspensionInspectionTool

e nextscheduledinspectionis due to be600mm long and12–20 mm wide. The lever can be NOTE NOTE

detailed in the paragraphs that The follow. lever, paragraphs the in detailed and classifythebushesaccordingly. VEHICLE G188-1

Issue 2,Aug09 3

UNCONTROLLED IF PRINTED rocking thesteeringwheelfrom si 11. Drop Arm Ball Joint. 0 RadiusArmAssembly andMountings. (Figure 2): 10. . PanhardRodAssembly andMountings. (Figure 2): 9. Inspection Procedure G 189-11details the procedure to reclaim the axle mounts forthe panhardrod,radius arm andrearlower link. 8. situations. componentssuspension may causerearaxle steer, wander,vibration ornoises during poweronandoff Issue 2,Aug09 VEHICLE G188-1 4 c. b. a. d. d. c. b. a. Bushes, rubbermounts, mounting boltsandshockabsorb radius arm andchecking forexcessive movement Check formovement in the axle bushesby placing a lever between the axle mounting brackets and the Check the bushesforseparated, extruding orperished rubber. 176 N.m (130lbf.ft). Check the radius arm fordamage andensurethat the mounting bolts andnuts aretensioned to sleeves. Check thechassisendbushes forwearandfreeplay. free play orseparation ofthe rubberbonding onthe metal sleeves. If anydoubtexists,placealever between the panhard No appreciable play should beevident in the bushes. theWith steering centralised andthe wheels on the ground,rockthe steering wheel from side to side. Check the bushesforseparated, extruding orperished rubber. 176 N.m (130lbf.ft). Check the panhardrodfordamage andensurethat the mounting bolts andnuts aretensioned to The drop arm ball joint (Figure 3) functionality is assessed by having an assistant assistant an having by isassessed functionality 3) (Figure arm joint ball drop The de to side while checking for free play in the ball joint. joint. ball the in freeplay for checking while side to de Figure 2FrontSuspension The radius arm’s functionality is assessed as follows asfollows is assessed arm’s radius The functionality The panhard rod functionality is assessed as follows asfollows isassessed functionality rod panhard The

ers aretobereplacedassets.EMEIVehicle and separation ofthe rubberbonding onthe metal rodmounting bracketsandtherodcheckfor ELECTRICAL ANDMECHANICAL ENGINEERING INSTRUCTIONS

UNCONTROLLED IF PRINTED 6 Manual SteeringBoxEndfloatandBacklash. float andbacklashinaccordan 16. 5 SteeringBoxandColumn. 15. 2 DragLinkandBall Joints. 12. ENGINEERING INSTRUCTIONS ELECTRICAL ANDMECHANICAL 4 SteeringDamperandMountings. 14. 3 TrackRodandBallJoints. 13. b. a. . SectorShaftEndfloat. a. b. a. b. a. b. a. (15–18 lbf.ft). Check the steering shaft universal joints forwearandthat the pinch bolts are tensioned to 20–25 N.m Check that the steering boxmounting bolts aretight. Inspect the damper forleaks, dents orother damage. Check that the mounting rubbers arenot perished or wornandmounting nuts aretight. disassembly ofthe steering box. Endfloat should not beconfusedwith steering wheel freeplay. adjuster screwandthe screwplug. The is evidentasverticalmovement of With anassistantrockingthest With Check thetrackrodfordamage. With anassistantrockingthest With Check the draglink fordamage. joints. joints. joints. joints. ce withEMEIVehicleG103.

The drag link functionality is assessed as follows (Figure 3): 3): (Figure asfollows isassessed functionality link drag The Thesteeringboxandcolumn func The track rod functionality is assessed as follows (Figure 3): 3): (Figure asfollows isassessed functionality rod track The Figure 3SteeringLinkages Themaximum sector shaft endfloat is 0.5mm. Thesector shaft end float The steering damper functionality is assessed as follows (Figure 3): 3): (Figure asfollows isassessed damper functionality steering The eering wheelfrom sidetoside,ch eering wheelfrom sidetoside,ch thesectorshaft,andis caused

Adjust the Land Roverthe 4x4manualAdjust steering boxend rectification ofendfloat requires the partial tionality isassessedasfollows: eck forfreemovement intheball eck forfreemovement intheball by playbetweenthesector shaft VEHICLE G188-1 Issue 2,Aug09

5

UNCONTROLLED IF PRINTED 18. Rear Lower Link. RearLower 18. 7 SteeringLockStops. lock. atfull arm wheel radius the the with tyrewalland the between 17. Issue 2,Aug09 VEHICLE G188-1 6 . SteeringWheelFreePlay. b. b. a. (3) (2) (1) Inspect the front flexible mount (link to chassis) asfollows: Check the lower link fordamage. components orby turning the sector shaft adjusting screwto reducebacklash. by backlashbetweentheworm a apparent due to the angle ofthe link (Figure 5). Check thattherubberbushingisincompressi plates. Check the flexible mounts for separated, extrudi Check that the mounting nuts arecorrectly tensioned to 176N.m (130lbf.ft). The rear lower link functionality is assessed as follows (Figure 4): 4): (Figure asfollows isassessed functionality link rearlower The Thesteeringlockstops must be adjust Figure 4RearCoilSpringSuspension Free playisFree normally caused by wornsteering linkage components or nd sectorshafts.Freeplaycan

on withthemetal endplates; a gap will be ng orperished rubberanddamage to the end ed toprovideaminimum clearanceof20mm

ELECTRICAL ANDMECHANICAL ENGINEERING INSTRUCTIONS be rectified by replacing worn

UNCONTROLLED IF PRINTED 0 RearLeafSpringsand Rocker Beam. 6): (Figure as follows 20. RearTopLinkand TopLinkBallJoint. 19. ENGINEERING INSTRUCTIONS ELECTRICAL ANDMECHANICAL e. d. c. b. a. g. f. e. d. c. b. a. h. c. play is 1mm (0.040in). Place aleverbetweenthetoplinkballjointandth lever between the mounting brackets andlink. Check formovement in the body to link bushesandseparation of the rubber bonding by placing a Check the bushesforseparated, extruding orperished rubber. Check that the top link ball joint is correctly tensioned to 176N.m (130lbf.ft). to 115N.m (85lbf.ft). damagelinksfor theand ensurethatCheck the body mounting bolts andnuts arecorrectly tensioned Check thewearplates Check the axle reboundstrap andretainers for damage. shackle bushesandseparation ofrubberbonding onthe metal sleeves. Place aleverbetweentheshacklebrackets and sp Check the shackle bushesforseparated, extruding orperished rubber. Check that the U-bolts arecorrectly tensioned to 128–142N.m (95–105lbf.ft). Check thespringsforsag. tensioned to 80–95N.m (60–70lbf.ft). the springleavesfordamageCheck andensure Check that the chassis pivot bolt is tensioned to 366N.m (270lbf.ft). (3) (2) (1) Inspect therearlink-to (4) or decelleration. when theclutchisengagedatpoint If thetoplinkballjointiswornoutitw Place aleverbetweentheaxlebracketandli Check the mounts forseparated, extruding orperished rubberanddamage. Check that the mounting nuts arecorrectly tensioned to 168–186N.m (12–137lbf.ft). the metal endplates. forth with the parkbrakeapplied. Therubberbushing must remain in partial contact with both If in doubt, lateral movement in the mount canbecheckedby rocking the vehicle back and Figure 5 Rear Lower LinkFrontFlexibleMountDetail Figure 5RearLower

on therockerbeams. -axle bushesasfollows: The rear leaf springs and rocker beam functionality is assessed isassessed beam rocker functionality and rearleafsprings The The top link functionality is assessed as follows (Figure 4): 4): (Figure asfollows isassessed functionality link top The NOTE of thevehiclemoving offoronacceleration ill normally exhibita

nk andcheckforfreeplayinthebushes. e axleandcheckforfreeplay.The maximum free that the shackle bolt lo bolt shackle the that ring andcheckforexcessivemovement inthe

loud ‘clunking’noise cking nutsarecorrectly VEHICLE G188-1 Issue 2,Aug09 7

UNCONTROLLED IF PRINTED 3 CoilSpringsandSeats. 23. 2 FrontandRearBumpRubbers. 22. 1 FrontandRear ShockAbsorbers. (Figure 6): 21. Issue 2,Aug09 VEHICLE G188-1 8 b. a. c. b. a. c. b. a. Check thatthespringseatretainer Check that the coil springs arenot brokenorsagged. G 197-13andarefunctional. Check thatthespringseatsare notdamaged. Ensure that the bump rubbersare not damaged. aretight. bolts mounting the that Ensure oscillation. oscillation. Bounce thevehiclethroughtwosusp Inspect the shockabsorbersforleaks, dents orother damage. securely. mountingthattheCheck rubbers arenot perished orwornandthat the mounting nuts aretightened Figure 6RearLeafSpringSuspension The functionality of the springs and seats is assessed as follows: asfollows: seatsisassessed and springs the of functionality The Thefunctionalityofthebump rubbers is assessedasfollows: The functionality of the shock absorbers is assessed as follows asfollows isassessed absorbers shock the of functionality The s havebeenfittedto4x4variants ension oscillationsandcheckthat

ELECTRICAL ANDMECHANICAL ENGINEERING INSTRUCTIONS in accordancewithEMEIVehicle the vehicle settleswithinone the

UNCONTROLLED IF PRINTED

24. Swivel PinBushesInitialInspection. Swivel follows: 24. ENGINEERING INSTRUCTIONS ELECTRICAL ANDMECHANICAL paragraphs shall to becarried out. PinBushesFullInspection. Swivel method)(DTI duringtheinitialinspecti 25. i. h. b. a. g. f. e. d. c. b. a. Place aDTIontheouterface ofthebrakedisc(Figure8). Adjust the preload to 4.5–9kg(10lb–20 lb by adding ordeleting shims from the upper swivel pin. If playisevidentattheupperswivelpin,placeaDial housing andcheckforplay. thefrontwheelsonground,placealever With resistance should be4.5–9kg(10–20lb) (Figure 7). the isovercome, inertia initial (afterthe swivel the turn to required effort the determine to pulling Check the upperswivel pin preload by attaching aspring balance to the track rod ball joint arm and Remove the swivel housing seal androtate the swivel pin housing from lock to lock fourto five times. Disconnect the track rodanddraglink from the swivel pin housing. Remove theroadwheels. Raise the front ofthe vehicle andsupport it onaxle stands. Loosen the front wheel nuts. Apply the hand-brakeandchockthe rearwheels. the axlehousingandstylusagainstswivel not toexceed0.3mm. an assistant depressing the brakepedal (to eliminat through the full procedure. indicativean giveto measurement andprevent unnecessary workbeforegoing swivelIf pin bushwearis suspected, carry out the following abbreviated procedure stands. not workunderneatharaisedvehiclewithoutitbeingsupportedonaxle Do whilst thevehicleisinraisedposi Personnel aretostayclearofthea Figure 7 Measuring Swivel PinRotatingResistance Figure 7MeasuringSwivel

on, oriftheinspectorisunsure, Iftheplaymeasured at Para Carry out an initial inspection of the swivel pin bushes as bushes pin swivel the of inspection initial an Carry out NOTE tion andunsupportedbysafetystands. rea between thewheelsandchassis rea

housing adjacentto the upper e wheelbearingplay),measure the play which is

between the lowerspringseatandswivel between TestIndicator (DTI) with the proceduredetailedinfollowing 24 exceeds0.3mm attheswivelpin

swivel pin.Then,with thebaseattachedto VEHICLE G188-1 Issue 2,Aug09 9

UNCONTROLLED IF PRINTED 6 Tyre Inflationand Wear. 26. Issue 2,Aug09 VEHICLE G188-1 7 PostInspectionRoadTest. 27. A298-2 10 j. l. k. o. n. m. q. p. a. e. d. c. b. possible andzerothe pointer. Place theDTIstylusonlowerspringseatinline w Note the DTI reading and then lowe then and DTIreading the Note itis until axle raise the anassistantdepressingthebrakepedal by With An averageof0.4mm (0.016in) or less indicates that the clearance is within specification. Repeat parak.tom. sixtimes andaveragethereadings. Apply adownward forceto the outer endofthe hub,andensurethat the DTIreturns to zero. Refit the roadwheels andlower the vehicle to the ground. Refit the swivel housing seal andreconnect the draglink andtrack rod. prior todrivingoff,centralisethesteeringboxa is horizontal; is horizontal; steering shimmy; steering wander; excessive playinthesteering; excessive bind in the steering; Do notplaceanybodypartsunderneath brake pedalisreleased,thevehiclemayrollofjack. not releasethebrakepedalwhile Do the axlestand. preload. If theclearanceexceeds0.4mm thenoverhau Inspectthetyre JUST Roadtestthevehicle clear oftheaxlestands. Figure 8DTIPosition r theaxlebackontostand. s inaccordancewith NOTE

axle isclearofthestand.If the vehiclewhileaxleisclearof and checkthefollowingareas: nd ensure the LandRoverd ensure nd hand, placeajackundertheouterendofhuband l theswivelpinhousingandset the

ith thetopofaxleas

EMEI Vehicle A291-1,291-5, and ELECTRICAL ANDMECHANICAL

ENGINEERING INSTRUCTIONS ecal onthesteeringwheel neartohorizontalas UNCONTROLLED IF PRINTED Report (GI041)istoberaiseddetailingthecomponents thatha stability. Unlesstheimmediate replacement 28. Recording Action. ‘ Part 2(RecordofInspection). ENGINEERING INSTRUCTIONS ELECTRICAL ANDMECHANICAL DO NOTUSE–XX g. f. i. h. noises oncornering,acceler rear axlesteer; unusual characteristics in the suspension orsteering likely to causeanunsafesituation. steering vibration; and ’ andthe inspection details recordedin the GM-120 (Record Book for Service Equipment) – Distributio List: Distributio AsstatedinPara3,wearsteeri (Sponsor: LVSPO,Lt B Vehicles Section) (Authority: ECO LVSPO73/09)

VEH G16.0-Code1( ation anddeceleration; of components thathavefailedthein END

ve failedtheinspection.The Maint Level) Level) Maint ng andsuspensioncomponent

spection is to occur,anInspection is spection hicle istobe classified VEHICLE G188-1 s will affectvehicle s Issue 2,Aug09 11