brake sensor LAND ROVER DISCOVERY 1995 Service Owner's Manual

MANIFOLD AND EXHAUST SYSTEM
7
REPAIR Refit
19.Ensure mating faces of inlet manifold and
cylinder head are clean.
20.Fit a new gasket, position inlet manifold to
cylinder head.
21.Fit nuts and bolts, tighten in the order shown to
the correct torque
25Nm
22.Position engine breather hose to manifold and
secure with bolts.
23.Connect fuel injector harness and intake air
temperature sensor multiplug.
24.Connect fuel hose to pressure regulator and
secure with clip.
25.Fit fuel pipe to fuel rail, tighten union to
10Nm
26.Connect vacuum hoses to manifold.
27.Position engine harness and cam cover brackets
to manifold, secure with bolts.
28.Connect breather hose and brake servo hose to
manifold, secure with clips.
29.Connect multiplug to fuel temperature sensor.
30.Connect breather hose to throttle housing and
secure with clip.
31.Connect throttle cable to cam and secure to
abutment bracket.
32.Connect coolant bypass hose to throttle housing.
33.Connect stepper motor and throttle
potentiometer multiplugs.
34.Connect air cleaner hose to throttle housing and
secure with clip.
35.Connect battery negative lead.
36.Adjust throttle cable.EXHAUST MANIFOLD GASKET - Mpi
Service repair no - 30.15.12
Remove
1.Raise vehicle.
2.Loosen 2 nuts securing downpipe to silencer
box.
3.Remove 4 nuts securing downpipe to exhaust
manifold.
4.Release downpipe from exhaust manifold.
5.Discard gasket.

MANIFOLD AND EXHAUST SYSTEM
9
REPAIR MANIFOLD CHAMBER GASKET - Mpi
Service repair no - 30.15.37
Remove
1.Disconnect battery negative lead.
2.Position absorbent cloth around fuel pipe to fuel
rail union. Loosen union to relieve pressure.
Re-tighten union.
3.Release clip and remove air cleaner to throttle
housing hose.
4.Disconnect stepper motor and throttle
potentiometer multiplugs.
5.Release clip and disconnect breather hose from
throttle housing.
6.Release throttle cable from abutment bracket.
7.Release throttle cable from cam. Remove
coolant bypass hose from throttle housing.
8.Disconnect fuel temperature sensor multiplug.
9.Release clip and disconnect brake servo hose
from manifold.

30MANIFOLD AND EXHAUST SYSTEM
10
REPAIR 10.Release clip and disconnect breather hose from
manifold.
11.Release 2 bolts securing camshaft cover
brackets to manifold.
12.Disconnect 4 vacuum hoses from manifold.
13.Remove 6 bolts securing manifold chamber to
lower manifold.
14.Remove manifold chamber and collect gaskets.
Refit
NOTE: For torque values.See
Specifications, torque, Torque Values
15.Ensure mating faces of manifold chamber and
lower manifold are clean.
16.Fit a new gasket, position manifold chamber to
lower manifold.
17.Fit bolts, tighten to the correct torque.
18.Connect vacuum hoses to manifold.
19.Position camshaft cover brackets to manifold,
secure with bolts.
20.Connect breather hose and brake servo hose to
manifold, secure with clips.
21.Connect multiplug to fuel temperature sensor.
22.Connect breather hose to throttle housing and
secure with clip.
23.Connect throttle cable to cam and secure to
abutment bracket.
24.Connect coolant bypass hose to throttle housing.
25.Connect stepper motor and throttle
potentiometer multiplugs.
26.Connect air cleaner hose to throttle housing and
secure with clip.
27.Reconnect battery negative lead.
28.Adjust throttle cable.

41TRANSFER GEARBOX
2
REPAIR Remove
1.Site vehicle on a ramp [hoist].
2.Disconnect battery negative lead.
3.Remove fan cowl from radiator.
4.Remove transfer gear lever knob and gaiter.
5.Raise vehicle on ramp [hoist].
6.Drain oil and refit plug.
7.Detach heat shield at front exhaust pipe to
manifold.
8.Disconnect electrics to Lambda sensors.
9.Remove catalytic converter assembly.
10.Remove chassis crossmember from under
gearbox.
11.Remove heat shield from speedometer cable at
transfer gearbox.
12.Remove clamp and disconnect speedometer
cable from transfer gearbox. Tie cable to one
side.
13.Mark for reassembly then disconnect propeller
shaft to output flange, tie to one side.
14.Repeat on front propeller shaft to output flange.
15.Remove bolts retaining silencer front and rear
securing brackets and tie silencer to one side.
16.Place four 30mm long spacers between top of
hoist and adaptor plate, at securing points, and
secure adaptor plate to hoist.17.Remove four central bolts from transfer gearbox
bottom cover, move hoist into position and
secure adaptor plate to transfer gearbox.
18.Adjust hoist to take weight of transfer gearbox.
19.Remove tie bar, transfer gearbox to main
gearbox.
20.Remove nuts and bolts securing right transfer
gearbox mounting bracket to chassis.
21.Repeat for left mounting bracket. Removal of
these fixings will also free speedometer
transducer bracket.
22.Remove right side mounting bracket to flexible
mounting rubber.
23.Lower hoist until rear brake drum clears
passenger footwell. Check engine does not
crush any components while lowering.
24.Loosen park brake adjustment nut.
25.Remove park brake drum.
26.Remove park brake assembly complete from
rear output flange.
27.Disconnect leads from transfer gearbox
temperature sensor and differential lock warning
light switch.
28.Remove banjo bolt from breather pipe, retrieve
sealing washers and lay pipe aside.
29.Remove split [cotter] pin and washers securing
differential lock to connecting rod and disconnect
rod from lever.
30.Select low range transfer gearbox position.
31.Remove high/low rod lower lock nut and remove
rod from yoke.
32.Position hoist jack channel under bell housing.
33.Using wooden block support the main gearbox
and bell housing.
34.Remove upper and lower bolts securing transfer
gearbox to main gearbox.
35.Fit guide studs 18G 1425 to main gearbox and
move transfer gearbox rearwards to detach.

ZF
3
REPAIR 19.Disconnect rear propeller shaft to output flange,
and tie to one side.
20.Repeat instructions 18 and 19 on front propeller
shaft to main gearbox.
21.Remove bolts retaining silencer front and rear
securing brackets and tie silencer to one side.
22.Disconnect oil cooler feed and return pipes from
bottom and side of main gearbox.
23.Release cooler pipes from clamp at engine sump
and remove distance piece.
24.Blank pipe ends and unions.
25.Move oil cooler pipes clear of transmission and
tie aside.
26.Disconnect selector cable from operating lever.
27.Disconnect inhibitor switch at multiplug.
28.Attach adaptor plate to hoist.
29.Remove two bolts from transfer gearbox rear
cover.
30.Raise hoist to align adaptor plate with transfer
gearbox and transmission. Secure to transfer
gearbox at rear cover with two bolts removed.
31.Adjust hoist to take weight of transmission.
32.Remove nuts and bolts securing right transfer
gearbox mounting bracket to chassis.
33.Repeat for the left mounting bracket. Removal of
these fixings will also free speedometer
transducer bracket
34.Remove right side mounting bracket to flexible
mounting rubber retaining nut.
35.Lower hoist until rear brake drum clears
passenger footwell. Check engine does not
crush any components while lowering.
36.Remove clip and clevis pin from park brake
lever.
37.Remove clip securing outer brake cable
38.The park brake cable is now free.
39.Disconnect leads from transfer gearbox
temperature sensor and differential lock warning
light switch.
40.Remove ties securing breather pipes to harness.
41.Remove bell housing access plate complete with
gasket.
42.Rotate engine, using crankshaft pulley, until two
access holes are visible in drive plate/ring gear
assembly through bell housing bottom cover
opening.
43.Identify an access hole and bolt hole to aid
reassembly.
44.Remove bolts securing drive plate to convertor
through access holes.
45.Rotate crankshaft half turn to access and
remove remaining bolts.
46.Disconnect oil dipstick tube at main gearbox.
47.Remove bolt at bell housing and detach dipstick
tube. Blank pipe end and union.
48.Position hoist jack channel under engine and
support using a wooden block.
49.Remove bell housing to engine securing bolts,
also detach harness bracket from bell housing.
50.Ease transmission rearwards to allow access to
secure torque converter in bell housing.
51.Lower hoist and complete removal of
transmission.
Refit
52.Ensure torque converter is retained in bell
housing.
53.Secure transmission to adaptor plate on lifting
hoist.
54.Raise hoist and locate transmission with engine.
55.Remove torque converter retainer.
56.Complete attachment of transmission to engine
and fit bell housing bolts. Fit the dipstick tube
bracket and harness bracket to their respective
bolts.
57.Complete refitting by reversing removal
procedure. Note the following important points.
58.Drive plate to torque converter bolts are to be
coated with Loctite 290 prior to assembly.
59.Refill transfer and main gearboxes with correct
grade oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
60.Check operation of parking brake and adjust as
necessary.
See SECTION 10, Maintenance,
Vehicle Interior

REAR AXLE AND FINAL DRIVE
1
DESCRIPTION AND OPERATION DESCRIPTION
The welded steel rear axle casing houses a separate
spiral bevel type differential unit, which is off set to the
right of the vehicle centre line. The differential unit
drives the rear wheels via the axle shafts and fully
floating hubs which are mounted on tapered roller
bearings.
Lubrication
The differential is lubricated with oil and the hub
bearings with grease. The hub bearings are fittedwith inner and outer seals. The outer seals prevent
the differential oil mixing with the hub grease and the
inner seals prevent dirt ingress into the hub.
Ventilation
Ventilation of the hub bearings is through the outer oil
seals and the differential ventilation pipe, which
terminates at a high level.
The wheel hubs on axles with ABS brakes share the
same construction to non ABS axles except for the
addition of a sensor ring 11 on the brake disc 10.
Rear axle hub
1. Axle casing
2. Ventilation pipe
3. Axle shaft
4. Wheel studs and hub
5. Wheel bearing stub axle
6. Wheel bearings (2)7. Inner hub seal
8. Outer hub/axle shaft seal
9. Hub lock plate, thrust washer and nuts (2)
10. Brake disc
11. Sensor ring, ABS

51REAR AXLE AND FINAL DRIVE
2
REPAIR REAR BRAKE DISC NON ABS
Service repair no - 70.10.11.
Remove
1.Remove rear hub assembly.
See Rear Hub
Assembly
2.Remove disc bolts.
3.Remove disc from rear hub.
Refit
4.Fit disc to rear hub.
5.Fit disc bolts. Tighten to
73 Nm.
6.Check total disc run out, this must not exceed
0,15 mm. If necessary reposition disc.
7.Fit rear hub assembly.See Rear Hub
Assembly
Disc reclamation
8.Check disc thickness. This dimension may be
reduced to minimum thickness of 12 mm.
Machine equal amounts off each face.REAR BRAKE DISCS ABS
Service repair no - 70.11.11.
Remove
1.Remove rear hub assembly.
See Rear Hub
Assembly
2.Remove five nyloc nuts.
3.Remove sensor ring.
4.Remove five hub to disc retaining bolts.
5.Remove disc from hub.
Refit
6.Fit disc onto hub.
7.Apply loctite 270 and fit hub to disc retaining
bolts. Tighten to
73 Nm.
8.Using new nyloc nuts fit sensor ring.
9.Check total disc run out, this must not exceed
0,15 mm. If necessary reposition disc.
10.Fit hub assembly.
See Rear Hub Assembly
Disc reclamation
11.Check disc thickness. This dimension may be
reduced to a minimum thickness of 12 mm.
Machine equal amounts off each face.

REAR AXLE AND FINAL DRIVE
3
REPAIR REAR HUB ASSEMBLY
Service repair no - 64.15.01
Remove
1.Place rear axle onto axle stands and remove
road wheel.
2.Release brake hose clips and remove brake
caliper bolts. Secure to one side.
WARNING: Take care not to kink brake
hose.
3.Remove five bolts and withdraw axle shaft.
4.Remove joint washer.
5.Bend back lock washer tabs.
6.Remove locknut and lock washer.
7.Remove hub adjusting nut.
8.Remove spacing washer.
9.Remove hub and brake disc assembly complete
with bearings.REAR HUB COMPONENTS
1. Sensor ring retaining nut ABS.
2. Axle shaft.
3. Axle shaft joint washer.
4. Axle shaft retaining bolt (five off).
5. Lock nut.
6. Lock washer.
7. Hub adjusting nut.
8. Spacing washer.
9. Outer bearing.
10. Hub.
11. Inner bearing.
12. Grease seal.
13. Brake disc.
14. Disc retaining bolt (five off).
15. Sensor ring ABS.

51REAR AXLE AND FINAL DRIVE
4
REPAIR Refit
10.Clean stub axle. Retract ABS sensor slightly
from sensor sleeve, if applicable
11.Fit hub assembly to stub axle.
12.Fit spacing washer.
13.Fit hub adjusting nut. Tighten to
61 Nm.
Back off adjusting nut 90°. Tighten to4 Nm.
This will give the required hub end float of
0,010mm
14.Fit a new lock washer.
15.Fit locknut. Tighten to61 Nm.
16.Tab over lock washer to secure adjusting nut
and locknut.
17.Using a new joint washer fit axle shaft to hub,
secure with five bolts. Tighten to
65 Nm.
18.Fit brake caliper. Tighten to82 Nm.
Secure brake pipes to axle casing.
19.If applicable, set ABS brakes sensor.
Push sensor in until it touches sensor ring then
rotate hub to set sensor.
20.Fit road wheel, remove axle stands and final
tighten road wheel nuts to
126 Nm.
21.Operate footbrake to locate brake pads before
driving vehicle.

REAR AXLE AND FINAL DRIVE
9
OVERHAUL REAR HUB ASSEMBLY
Service repair no - 61.15.13.
Overhaul
1.Remove rear hub assembly.
See Repair, Rear
Hub Assembly
2.Remove outer bearing.
3.Remove five nyloc nuts and withdraw ABS
sensor ring, if applicable.
4.Mark, for reassembly, position of hub to brake
disc.5.Remove five bolts and separate hub from brake
disc.
WARNING: A maximum of two road wheel
retaining studs can be renewed. Should
more studs be unserviceable fit new hub
with studs.
6.Remove grease seal and inner bearing from
hub.
7.Remove inner and outer bearing tracks.
REAR HUB COMPONENTS
1. Sensor ring retaining nut ABS.
2. Axle shaft.
3. Axle shaft joint washer.
4. Axle shaft retaining bolt (five off).
5. Lock nut.
6. Lock washer.
7. Hub adjusting nut.
8. Spacing washer.9. Outer bearing.
10. Hub.
11. Inner bearing.
12. Grease seal.
13. Brake disc.
14. Disc retaining bolt (five off).
15. Sensor ring ABS.