drain bolt LAND ROVER DISCOVERY 1995 Service Service Manual

ZF
11
REPAIR CONTROL UNIT
Remove
1.Site vehicle on a four post ramp [hoist].
2.Disconnect battery negative lead.
3.Raise vehicle.
4.Drain oil and refit plug with new seal.
5.Detach heat shield at front exhaust pipe to
manifold.
6.Disconnect electrics from Lambda sensors.
7.Remove catalytic converter assembly.
8.Remove chassis cross-member from under
gearbox.
9.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
10.Remove clamps securing oil sump. Note their
locations for refit and withdraw sump.
11.Remove gasket and clean gasket mating faces.
12.Remove securing screws and detach oil screen
and suction pipe, taking care to retain suction
pipe spacer, discard 'O' ring seal.
13.Remove securing screws and detach control unit
from casing.

ZF
13
REPAIR KICKDOWN CABLE
Service repair no - 44.15.01
Remove
1.Site vehicle on a four post ramp [hoist].
2.Select neutral 'N' gear lever.
3.Disconnect battery negative lead.
4.Disconnect kickdown cable at throttle linkage.
5.Release outer cable locknut.
6.Disconnect cable from mounting bracket.
7.Release cable from bracket attached to cylinder
head.
8.Feed cable through to underside of vehicle.
9.Raise vehicle on ramp [hoist].
10.Drain oil and refit plug with new seal.
11.Detach heat shield at front exhaust pipe to
manifold.
12.Disconnect electrics from Lambda sensors.
13.Remove catalytic converter assembly.
14.Remove chassis cross-member from under
gearbox.
15.Disconnect dipstick tube at oil sump. Loosen
securing bolt at bell housing and move dipstick
aside.
16.Remove clamps securing oil sump. Note their
locations for refit, and withdraw sump.
17.Pull kickdown inner cable to fully open valve
cam. Wedge cam in this position.
18.Release cable from cam by pushing inner cable
into outer casing and detaching cable nipple
from cam.
19.Using special tool LST112 compress cable tangs
and remove cable from gearbox.
20.If cable is to be refitted remove 'O' ring seal and
clean cable assembly.
Refit
21.Fit new 'O' ring seal to cable and lubricate seal.
22.Fit cable to gearbox casing ensuring it is
correctly seated.
23.Fit inner cable nipple to its location on cam.
NOTE: When a new cable is fitted, to help
locate nipple to cam, introduce a curve
into the cable. Do not bend or kink cable.24.Remove wedge from cam and ensure nipple
remains engaged.
25.Feed free end of cable assembly into engine
compartment.
26.Refit oil pan using a new gasket.
27.Connect dipstick tube to oil sump and tighten
bolt at bell housing.
28.Refit chassis cross-member
29.Refit catalytic converter assembly
30.Connect electrics to Lambda sensors.
31.Connect heat shield front pipe to manifold.
32.Lower vehicle on ramp [hoist].
33.Fit cable to bracket at cylinder head.
34.Locate cable in mounting bracket, do not tighten
locknut.
35.Fit cable to throttle linkage.
36.Ensure throttle linkage is fully closed.
37.Adjust outer cable to achieve a gap of 0,25 to
1,25mm (dimension 'A') between end of outer
cable and crimped collar on inner cable.
38.Tighten locknuts and recheck gap.
NOTE: If fitting a new cable, and collar on
inner cable is loose, measure distance 'B'
on old cable. Crimp collar on new cable to
this dimension.
39.Reconnect battery negative lead.
40.Refill gearbox oil using correct grade of oil.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids

44AUTOMATIC GEARBOX
14
REPAIR EXTENSION HOUSING
Service repair no - 44.20.18
Remove
1.Remove transfer gearbox.
See TRANSFER
GEARBOX, Repair, LT230T Transfer Gearbox
2.Drain oil from automatic gearbox.
3.Remove bolts securing left hand mounting
bracket to extension housing and withdraw
bracket.
4.Remove transfer gear lever housing securing
bolts and move housing aside.
5.Remove securing bolts and withdraw extension
housing from over coupling shaft. Remove and
discard gasket.
6.Place extension housing on bench and remove
oil seal.
7.Ensure that all surfaces are clean and housing is
free from damage. If damage is found and
housing has to be renewed remove dowels from
face of existing housing and fit to new housing.
8.Using special tool LST108 fit new oil seal to
housing.Refit
9.Fit extension housing to gearbox, with a new
gasket, ensuring oil seal is not damaged by
extension shaft.
10.Secure housing with nine bolts. Tighten to
23
Nm.
11.Refit transfer gear lever housing to top of
extension housing. Tighten to
25 Nm.
12.Refit mounting bracket to extension housing.
Tighten to
52 Nm.
13.Refit transfer gear box.See TRANSFER
GEARBOX, Repair, LT230T Transfer Gearbox
14.Refill automatic gearbox lubrication system with
correct grade of oil.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids

ZF
15
REPAIR GOVERNOR ASSEMBLY
Service repair no - 44.22.01
Remove
1.Remove transfer gearbox.
See TRANSFER
GEARBOX, Repair, LT230T Transfer Gearbox
2.Drain oil from automatic gearbox.
3.Remove bolts securing left hand mounting
bracket to extension housing and withdraw
bracket.
4.Remove transfer gear lever housing securing
bolts and move housing aside.
5.Remove extension housing ensuring seal is not
damaged, remove and discard gasket.
6.Remove extension shaft retaining bolt, withdraw
shaft and discard 'O' ring seal. If Tdi vehicle
remove spacer.
7.Remove governor assembly.
8.Remove park gear from governor assembly.
9.Detach governor housing.
10.Remove security clip and counter weight.
11.Remove and discard 'O' ring seal from output
shaft and three seal rings from 'F' clutch
housing.
12.Clean all components.
13.If necessary detach parking pawl by removing
guide plates and withdrawing mechanism.Refit
14.Refit parking pawl mechanism if removed.
15.Fit and lubricate new seal rings to 'F' clutch
housing shaft, ensure they are correctly seated.
16.Apply petroleum jelly to a new 'O' ring seal. Fit to
output shaft
17.Fit park gear to governor assembly tightening
screws to correct torque.
18.Fit governor assembly to output shaft.
19.Fit extension shaft with spacer if Tdi. Fit new 'O'
ring under bolt head.
20.Fit extension housing, avoid damaging seal.
Tighten to
23 Nm.
21.Refit transfer gear lever housing to extension
housing.
22.Refit mounting bracket to extension housing.
Tighten to
52 Nm.
23.Refit transfer gearbox.See TRANSFER
GEARBOX, Repair, LT230T Transfer Gearbox
24.Refill automatic gearbox with correct grade of oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids

REAR AXLE AND FINAL DRIVE
1
REPAIR REAR AXLE
Service repair no - 51.25.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
the axle when lowering or repositioning
axle.
1.Drain brake system.
2.Support chassis rear.
3.Remove road wheels.
4.Support axle weight with hydraulic jack.
5.Disconnect ABS wiring harness multi-plug at
jump hose bracket, if applicable.
6.Disconnect shock absorbers.
7.Disconnect flexible brake hose at connection
under floor.
8.Disconnect lower links at axle.
9.Mark differential and propeller shaft flanges with
identification marks for assembly. Remove four
nuts and bolts. Lower propeller shaft and tie to
one side.10.Disconnect pivot bracket ball joint at axle
bracket.
11.Release bolts and remove coil spring retaining
plates.
12.Lower axle and remove road springs.
13.Disconnect anti-roll[sway] bar links to axle.
See
REAR SUSPENSION, Repair, Anti-Roll[Sway]
Bar Ball Joint Links
14.Remove axle assembly.
Refit
15.Position axle and fit lower links. Tighten to
176
Nm
16.Reverse removal procedure.
17.Tighten pivot bracket ball joint to axle to
176 Nm.
18.Tighten propeller shaft to differential drive flange
to
47 Nm
19.Bleed brake system.See BRAKES, Repair,
Brake System Bleed

FRONT AXLE AND FINAL DRIVE
3
OVERHAUL FRONT STUB AXLE, CONSTANT VELOCITY JOINT
AND SWIVEL PIN HOUSING NON ABS
Service repair no - 60.15.43.
Remove stub axle, axle shaft and constant
velocity joint.
1.Remove front hub assembly.
See Repair,
Front Hub Assembly
2.Drain swivel pin housing and refit plug.
3.Remove six bolts retaining stub axle to swivel
housing.
4.Remove mud shield.
5.Remove stub axle and joint washer.
6.Pull out axle shaft and constant velocity joint
from axle casing.
Remove constant velocity joint from axle shaft
7.Hold axle shaft firmly in a soft jawed vice.
8.Using a soft mallet drive constant velocity joint
from shaft.
9.Remove circlip and collar from axle shaft.
Constant velocity joint
10.Mark positions of constant velocity joint, inner
and outer race and cage for reassembly.
11.Swivel cage and inner race to remove balls.

FRONT AXLE AND FINAL DRIVE
7
OVERHAUL Fit driveshaft and stub axle
59.Insert axle shaft, and when differential splines
are engaged, push assembly in fully.
CAUTION: Take care not to damage axle
shaft oil seals.
60.Place a new joint washer in position on swivelpin
housing to stub axle mating face. Coat threads
of stub axle bolts with Loctite 270.
61.Fit stub axle with flat at 12 o'clock position.
CAUTION: Ensure that constant velocity
joint bearing journal is butted against
thrust ring on stub axle. Before stub axle
is secured.
62.Place mud shield in position and secure stub
axle to swivel pin housing with six bolts and
tighten evenly to
65 Nm.
63.Fit brake jump hoses to brake jump hose
bracket.
64.Fit front hub complete assembly.
See Repair,
Front Hub Assembly
65.Check swivel pin housing oil drain plug is fitted.
66.Fill swivel assembly to correct level, with new oil.
See SECTION 10, Maintenance, Under
Vehicle Maintenance
67.Set steering lock stop bolts to provide a
clearance of 20mm.
See STEERING,
Adjustment, Steering Lock Stops
FRONT STUB AXLE, CONSTANT VELOCITY JOINT
AND SWIVEL PIN HOUSING ABS
Service repair no - 60.15.43.
Remove stub axle, axle shaft and constant
velocity joint.
1.Remove front hub assembly.
See Repair,
Front Hub Assembly
2.Drain swivel pin housing and refit plug.
3.Remove six bolts retaining stub axle to swivel
housing.
4.Remove mud shield.
5.Remove stub axle and joint washer.
6.Pull out axle shaft and constant velocity joint
from axle casing.

FRONT AXLE AND FINAL DRIVE
11
OVERHAUL Fit driveshaft and stub axle
59.Insert axle shaft, and when differential splines
are engaged, push assembly in fully.
CAUTION: Take care not to damage axle
shaft oil seals.
60.Place a new joint washer in position on swivelpin
housing to stub axle mating face. Coat threads
of stub axle bolts with Loctite 270.
61.Fit stub axle with flat at 12 o'clock position.
CAUTION: Ensure that constant velocity
joint bearing journal is butted against
thrust ring on stub axle. Before stub axle
is secured.
62.Place mud shield in position and secure stub
axle to swivel pin housing with six bolts and
tighten evenly to
65 Nm.
63.Fit brake jump hoses to brake jump hose
bracket.
64.Fit front hub complete assembly.
See Repair,
Front Hub Assembly
65.Check swivel pin housing oil drain plug is fitted.
66.Fill swivel assembly to correct level, with new oil.
See SECTION 10, Maintenance, Under
Vehicle Maintenance
67.Set steering lock stop bolts to provide a
clearance of 20mm.
See STEERING,
Adjustment, Steering Lock Stops
68.Fit ABS brake sensor.See BRAKES, Repair,
Sensors - Front

STEERING
5
REPAIR POWER STEERING SYSTEM - BLEED
Service repair no - 57.15.02
1.Ensure fluid in reservoir reaches dipstick
maximum.
2.Run engine to normal operating temperature.
3.Recheck and correct reservoir fluid level.
NOTE: During instructions 4 to 6, maintain
maximum fluid level in reservoir. Do not
increase engine speed or move steering
wheel.
4.With engine at idle speed, loosen bleed screw.
When fluid seeps past bleed screw retighten
screw.
5.Check fluid level.
6.Clean away fluid around bleed screw.
7.Check hose connections, pump and steering box
for fluid leaks by holding steering on full lock in
both directions.
CAUTION: Do not maintain this pressure
for more than 30 seconds in any one
minute to avoid overheating fluid and
possibly damaging seals.
8.Carry out road test.POWER STEERING FLUID RESERVOIR
Service repair no - 57.15.08
Remove
1.Remove undertray.
2.Position drain tin beneath reservoir.
3.Loosen mounting bracket clamp bolt, raise
reservoir to gain access to pipe clamps.
4.Loosen clamps, disconnect feed and return
hoses from reservoir, allow fluid to drain.
CAUTION: Plug the connections.
5.Remove reservoir.
CAUTION: Discard fluid drained from
system. Do not allow fluid to contact
paintwork, if spilled, remove fluid and
clean area with warm water.

57STEERING
6
REPAIR Refit
6.Position reservoir, connect feed and return
hoses and tighten clamps to
3 Nm.
7.Fit reservoir in clamp, tighten clamp bolt.
8.Fill reservoir to 'MAX' mark on dipstick with
power steering fluid.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids
9.Fit undertray.
10.Bleed power steering system.
See Power
Steering System - Bleed
POWER STEERING PUMP DRIVE BELT
Service repair no - 57.20.02
NOTE: For details of drive belt remove and
refit.
See ENGINE, Repair, Drive Belt
POWER STEERING PUMP - V8i
Service repair no - 57.20.14
NOTE: The power steering pump is not
serviceable. Fit new pump if worn or
damaged.
Remove
1.Disconnect battery negative lead.
2.Remove drive belt from steering pump.
See
ENGINE, Repair, Drive Belt
3.Remove undertray.
4.Remove fan blades and viscous coupling.
See
COOLING SYSTEM, Repair, Viscous
Coupling, Fan Blades, Pulley and Fan Cowl
5.Position drain tin beneath steering pump.
6.Using a 9 mm Allen key to restrain steering
pump pulley, remove 3 bolts securing pulley to
pump; remove pulley.