service LAND ROVER DISCOVERY 1995 Workshop Manual

STEERING
19
REPAIR DRAG LINK AND DRAG LINK ENDS
Service repair no - 57.55.17
Remove drag link
1.Check front wheel alignment.
See Adjustment,
Front Wheel Alignment
2.Ensure wheels are positioned straight ahead
during following procedure.
3.Place vehicle on a hoist, or support front axle on
axle stands.
4.Remove right front road wheel.
5.Disconnect drag link ball joint at swivel housing
arm, using extractor LRT-57-018.
6.Disconnect drag link ball joint at drop arm using
LRT-57-018.
7.Remove drag link.
Remove drag link ends
8.Loosen clamp bolts.
9.Unscrew ball joints.
10.Clean internal threads in drag link.Refit drag link ends
11.Fit replacement ends. Loosely fit clamp bolts.
12.Set ball joints to drag link distance to 28.5mm as
shown.
13.Adjust ball pin centres to nominal length of
924.0mm. this length is adjusted during refit.
14.Centralise steering box.
See Adjustment,
Centralise Steering Box
15.Align steering wheel, if necessary.See
Steering Wheel
Refit drag link
CAUTION: Fit new drag link if existing drag
link is damaged or bent. No attempt
should be made to repair it.
16.Fit drag link. Tighten ball-joint nuts to
40 Nm.
17.Check steering lock stops.See Adjustment,
Steering Lock Stops
18.Ensure full steering travel is obtained between
lock stops. Adjust drag link length to suit.
19.Tap ball joints in direction shown, so both pins
are in same angular plane.
20.Tighten clamp bolts to
14 Nm.
21.Reverse removal procedure. 3 and 4.
22.Road test vehicle.
23.If driving straight ahead and steering wheel is
offset by 0°to±5°in either direction. Remedy by
adjusting drag link length.
WARNING: To correct steering wheel
deviations greater than±5°. Remove and
reposition steering wheel.
See Steering
Wheel

STEERING
1
OVERHAUL POWER STEERING BOX
Service repair no - 57.10.07
Overhaul
NOTE: Overhaul of steering box should
not be carried out during the warranty
period.
WARNING: Wear safety glasses while
removing and refitting circlips and
retaining ring.
CAUTION: Absolute cleanliness is
essential when overhauling power steering
box.
1.Remove steering box from vehicle.See Repair,
Power Steering Box
Remove drop arm using extractor LRT-57-012.
Loosen drop arm securing nut, but do not
remove before using extractor. Remove dirt
excluder from output shaft.
2.Drain oil, remove blanking plugs and bleed
screw. Hold steering box over suitable container,
turn input shaft from lock to lock, until oil is
drained. Refit bleed screw.
3.Rotate retainer ring until one end is 12 mm from
extractor hole. Using a drift through hole in
cylinder, lift retaining ring from groove in cylinder
bore.
4.Remove retainer ring, using a screwdriver.
5.Turn input shaft (left lock on left hand drive, right
lock on right hand drive) until piston pushes out
cover. Turn input shaft fully in opposite direction,
applying pressure to piston.
6.Remove set screw retaining rack pad adjuster.
7.Remove rack adjuster and pad.
8.Remove sector shaft adjuster locknut.
9.Remove four bolts from sector shaft cover.
10.Screw in sector shaft adjuster until cover is
removed.
NOTE: Sealant is applied to hexagon
socket to 'tamperproof' sector shaft
adjuster
11.Slide out sector shaft.

STEERING
1
SERVICE TOOLS POWER STEERING BOX
LRT-57-012 Drop arm extractor
LRT-57-007 'C' Wrench
LRT-57-006 Worm adjusting wrench
LRT-57-019 Ring expander

57STEERING
2
SERVICE TOOLS
LRT-57-020 Ring compressor
LRT-57-021 Seal saver, sector shaft
LRT-57-016 Seal saver, valve and worm
LRT-57-017 Torque setting tool

STEERING
3
SERVICE TOOLS
LRT-57-018 Ball joint remover
LRT-57-005 Pressure gauge
LRT-57-001 Test adaptor
LRT-57-022 Pressure test adaptors

FRONT SUSPENSION
1
REPAIR SELF LOCKING NUTS
WARNING: Where self locking nuts are
removed, they must be replaced with new
nuts of same specification.
PANHARD ROD
Service repair no - 60.10.07.
Remove
1.Remove fixings at mounting arm.
2.Remove fixings at axle bracket.
3.Remove Panhard rod.
4.Press out flexible bushes. Ensure the steel
tubing locates on the outer edge of the bush and
not on the rubber inner.
Refit
5.Fit replacement bushes.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
6.Reverse removal procedure. 1 to 4. Tighten to
88Nm
RADIUS ARM
Service repair no - 60.10.16.
Remove
1.Loosen road wheel retaining nuts.
2.Raise front of vehicle. Support chassis on stands
and remove wheel.
3.Support front axle weight with jack.
4.Remove radius arm to chassis side member
fixings.
5.Disconnect track rod at ball joint.
6.Remove fixings, radius arm to axle.
7.Lower radius arm front end to clear axle and
remove from vehicle.

60FRONT SUSPENSION
2
REPAIR
8.Press out flexible bushes.
Refit
9.Press in replacement bushes.
CAUTION: When pressing in new bushes
press on outer edge of bush and not
rubber inner.
10.Reverse removal procedure. 1 to 8.
Tighten fixings to following torques:
Radius arm to chassiss
176Nm
Radius arm to axle197Nm
FRONT SHOCK ABSORBER
Service repair no - 60.30.02.
Remove
1.Loosen road wheel retaining nuts.
2.Support chassis on stands and remove road
wheel.
3.Support axle weight with jack.
4.Remove shock absorber lower fixing and
withdraw cupwasher, rubber bush and seating
washer.
5.Remove four shock absorber bracket fixings.
6.Withdraw shock absorber and bracket complete.

FRONT SUSPENSION
3
REPAIR 7.Withdraw lower seating washer, rubber bush and
cupwasher.
8.Remove fixings, shock absorber to mounting
bracket.
9.Withdraw mounting bracket.
10.Lift off top seating washer, rubber bush and
cupwasher.
Refit
11.Reverse removal procedure. 1 to 10.FRONT ROAD SPRING
Service repair no - 60.20.11.
Remove
1.Remove front shock absorber.
See Front
Shock Absorber
CAUTION: Avoid over stretching brake
hoses. If necessary loosen hose connector
locknuts to allow hoses to follow axle.
2.Lower axle sufficient to free road spring.
3.Withdraw road spring.
4.Withdraw shock absorber bracket securing ring.
Refit
5.Fit shock absorber bracket retaining ring. Retain
in position with a nut.
6.Reverse 2 and 3.
7.Remove nut retaining securing ring.
8.Fit front shock absorber.

60FRONT SUSPENSION
4
REPAIR BUMP STOP
Service repair no - 60.30.10.
Remove
1.Remove fixings.
2.Remove bump stop.
Refit
3.Position bolts in slots in chassis brackets.
4.Fit bump stop, secure with washers and nuts.

FRONT SUSPENSION
5
REPAIR ANTI-ROLL[SWAY] BAR ASSEMBLY FRONT
Service repair no - 60.10.01
KEY
1. Anti-roll[sway] bar
2. Rubber bush
3. Strap
4. Nut, bolt, washer5. Nut and washer
6. Castellated nut and cotter pin
7. Ball joint link arm
Remove
1.Mark for reassembly position of rubber bushes
on anti- roll[sway] bar.
2.Remove four nuts, bolts and washers securing
two bush straps.
3.Remove nuts, bolts, washers and rubber bushes
from ball joint links and remove anti-roll[sway]
bar.Refit
4.Position bushes on anti-roll[sway] bar. Ensure
split points towards axle on RH bush and away
from axle on LH bush.
5.Fit anti-roll[sway] bar with two straps. To ensure
correct fit angled sides of bar should point down
as shown. Loosely fit the bolts, washers and
nyloc nuts.
6.Fit bolt, washers and rubber bushes. Using new
nuts fit anti-roll[sway] bar to ball joint links.
Tighten to
68Nm.
7.Tighten nuts securing straps to30Nm