Body and Frame — Vehicle Details and Tolerance Checks (Defender 2007+)

Chassis

The chassis on all variants of the Defender is made of box-section profiles and has a frame structure. The structural material is steel 2 mm thick, treated with zinc phosphate and having a cathode coating. The rear cross member is treated with mastic.



The outriggers and tilt brackets are welded to the chassis support suspension and axle members and are also used as body support points. A removable box-section cross member is installed between the two chassis spars, making it easier to remove the gearbox and transfer case.

In case of damage to the chassis, a large number of elements are provided, including the support outriggers of the body, cross members and support brackets of the trailing arms. ALWAYS use genuine parts that are under warranty and that match the original equipment specification and are installed in accordance with Land Rover's BS 5135 welding standard.

Body

All body panels, with the exception of the front panel baffle, are made from aluminum alloy. The front wheel arches are galvanized steel for optimum protection. Most panels are also treated with zinc phosphate and are cathodic coated with polyester putty. The panels are bolted to a welded chassis.

Chassis frame alignment

After assembling the vehicle, you can check the squareness of the chassis by proceeding as follows:

• 1. Install the car on a flat horizontal platform.
• 2. Mark measurement points approximately at the locations shown in LR4412M. Make sure the markings are symmetrical on each side of the chassis frame.
• 3. Fix a plumb bob against each of the measurement points in turn and mark the floor directly below the plumb bob.
• 4. Move the vehicle and measure diagonally between the marks made on the floor. If the chassis geometry is not violated, the length of the diagonals between the respective measurement points must be within 9.50 mm.
• 5. Checking the dimensions of the chassis frame can be carried out when the upper structure of the car is removed, according to the corresponding drawing and legend.

Chassis 90

Chassis control dimensions

No./Letter	Size
A	Front dimensions
B	Chassis dimensions
C	Center line of the front axle
D	Centerline of the rear axle
1	239.0 - 236.5 mm
2.	82.0 - 79.5 mm
3.	633 mm
4.	2420.6 - 2418.6 mm
5.	2306.4 - 2305.4 mm
6.	981.2 - 978.7 mm
7.	182.7 mm
8.	41.5 - 37.0 mm
9.	252 - 250 mm
10.	110 mm
11.	2360 mm - Wheelbase
12.	636 - 634 mm
13.	488 - 482 mm
14.	488 - 482 mm
15.	3431.1 - 3426.1 mm
16.	588.3 - 586.3 mm
17.	2313.8 - 2311.8 mm
18.	590.5 mm
19.	295.25 mm
20.	519.30 - 517.30 mm
21.	259.80 - 258.50 mm
22.	1242.6 - 1240.6 mm
23.	642.5 - 639.5 mm
24.	750.9 mm
25.	439.5 - 436.5 mm
26.	136.5 mm
27.	299.5 - 295.5 mm
28.	103 - 100 mm
29.	131.5 - 126.5 mm
30.	705.5 - 704.5 mm
31.	705.5 - 704.5 mm
32.	42.2 - 40.2 mm
33.	491 - 486 mm
34.	594.2 - 593.4 mm
35.	283.0 - 282.2 mm
36.	32.25 - 31.25 mm
37.	397 - 395 mm

Dimensions for motor installation - section VV

NOTE: Engine support bracket dimensions apply to all models.

Dimensions for Tdi

Size	Meaning
A	276.5 mm
B	553 mm
C	127.9 mm
D	317.4 mm
E	4°

Dimensions for Td5

Size	Meaning
A	273.2 mm
B	546.5 mm
C	187.8 mm
D	347.3 mm
E	4°

Chassis 110

Chassis control dimensions

No./Letter	Size
A	Front dimensions
B	Chassis dimensions
C	Center line of the front axle
D	Centerline of the rear axle
1.	4148 - 4143 mm
2.	4009.5 - 4005 mm
3.	978.7 - 981.2 mm
4.	22 - 20 mm
5.	252 - 250 mm
6.	239 - 236.5 mm
7.	3023.3 - 3022.3 mm
8.	3030.7 - 3028.7 mm
9.	155 - 153 mm
10.	871.2 - 869.2 mm
11.	2794 mm - Wheelbase
12.	488 - 482 mm
13.	488 - 482 mm
14.	82 - 79.5 mm
15.	750.9 mm
16.	750.9 mm
17.	440.5 - 435.5 mm
18.	440.5 - 435.5 mm
19.	299.5 - 295.5 mm
20.	500 - 495 mm
21.	500 - 495 mm
22.	594.2 - 593.4 mm
23.	594.2 - 593.4 mm
24.	283 - 282.2 mm
25.	283 - 282.2 mm
26.	1970 - 1968 mm
27.	642.9 - 639.5 mm
28.	750.9 mm
29.	290.5 mm
30.	295.5 mm
31.	299.5 - 295.5 mm
32.	103 - 100 mm
33.	1177.5 - 1175.5 mm
34.	1692.5 - 1689.5 mm
35.	2610 - 2606 mm
36.	2040.5 - 2037.5 mm
37.	1912.5 - 1909.5 mm
38.	1359 - 1357 mm
39.	1573 - 1571 mm
40.	270 - 268 mm
41.	665.5 - 663.5 mm
42.	440 - 438 mm
43.	32.25 - 31.25 mm

Section VV runs along the engine mounts. Dimensional information is based on engine mounting dimensions for chassis 90.

Chassis 130

Chassis control dimensions

NOTE: The above dimensions are for the Land Rover 130 chassis frame. For additional dimensions, refer to the Land Rover 110 chassis frame drawing and reference dimensions.

No./Letter	Size
A	Front dimensions
B	Chassis dimensions
C	Center line of the front axle
D	Centerline of the rear axle
E.	Chassis dimensions, section AA
1.	663.0 mm, for reference only
2.	3569.3 - 3567.3 mm
3.	2421.8 - 2419.8 mm
4.	2317.5 - 2314.5 mm
5.	2188.3 - 2185.3 mm
6.	2119.5 - 2117.3 mm
7.	1990 - 1988 mm
8.	1970 - 1968 mm
9.	2401.8 - 2399.8 mm
10.	110.0 mm, for reference
11.	149.7 - 146.7 mm reference size
12.	3225.8 mm, wheelbase

Information about clearances and tolerances

The information below is intended as a guide for technicians to install exterior panels and body trim. Its purpose is to ensure the correct docking of the elements and an acceptable appearance of the car.

• Section AA, gap between hood and fender A = 3 - 8 mm. Parallelism must be maintained within 2 mm
• Section BB, clearance between the wing and the bottom of the strut «A» B = 0 mm. Tolerance =±1mm
• Section CC, gap between wing and sill C = 0 mm. Tolerance =±1mm
• Section DD, gap between the window opening and the door frame D = 5 - 9 mm
• Section EE, gap between door frame and roof E = 7 - 11 mm
• Section FF, clearance between front/rear door and 'B'/'C' pillar F = 7 - 11 mm

• Section GG, gap between door and threshold G = 7 - 11 mm. Door edge in relation to the threshold = 0 + 2 mm
• Section HH, gap between rear door and body H = 7 - 11 mm Edge of door to body = 0 + 3 mm
• Section JJ, gap between the lower side of the body and the body J = 0 - 4 mm Parallelism must be ensured within 2 mm

• Section KK, gap between roof and tailgate K = 7 - 9 mm. Tolerance =±1mm
• Sections LL and NN, gap between body side and tailgate L = 6 - 7 mm. Tolerance =±1mm
• Cross-section MM, gap between the rear of the body and the tailgate M = 7 - 9 mm