lock LAND ROVER DISCOVERY 1995 Workshop Manual

FRONT AXLE AND FINAL DRIVE
1
OVERHAUL FRONT DIFFERENTIAL
Service repair no - 54.10.07.
Overhaul
The front and rear differentials are the same. When
overhauling front differential.
See REAR AXLE AND
FINAL DRIVE, Overhaul, Axle Differential
Assembly
FRONT HUB
Service repair no - 60.26.14.
Overhaul
1.Remove front hub assembly.
See Repair,
Front Hub Assembly
2.Remove outer bearing.
3.Mark, for reassembly, relationship between hub
and brake disc, if original hub is to be refitted.
4.Remove five bolts and separate hub from brake
disc.5.Drift out grease seal and inner bearing from hub
and discard seal.
6.Drift out inner and outer bearing tracks.
7.Clean hub and drift in inner and outer bearing
tracks.
8.Pack hub inner bearing with recommended
grease and fit to hub.
HUB COMPONENTS
1. Dust cap.
2. Drive shaft circlip.
3. Drive shaft shim.
4. Drive member.
5. Drive member joint
washer.
6. Drive member
retaining bolt.
7. Lock nut.8. Lock washer.
9. Hub adjusting nut.
10. Spacing washer.
11. Outer bearing.
12. Hub.
13. Inner bearing.
14. Grease seal.
15. Brake disc.
16. Disc retaining bolt.

FRONT AXLE AND FINAL DRIVE
5
OVERHAUL Swivel pin housing
22.Remove bolts securing oil seal retaining plate
and joint washer. Release assembly from swivel
pin housing.
NOTE: Removal of oil seal and retaining
plate is achieved when swivel bearing
housing is removed.
23.Remove two bolts, retaining lower swivel pin to
housing.
24.Remove brake disc shield bracket.
25.tap lug to remove lower swivel pin and joint
washer.
26.Remove two bolts retainin brake hose bracket
and top swivel pin.
27.Remove bracket, top swivel pin and shims.
28.Remove swivel pin housing while retrieving
lower and upper bearings.
Swivel bearing housing
29.Remove lower bearing track from swivel bearing
housing.
NOTE: Use upper bearing opening to gain
access to lower bearing track.
30.Remove seven bolts retaining swivel bearing
housing to axle case.
31.Remove inner oil seal from back of housing.
32.Remove top bearing track from swivel bearing
housing.
NOTE: Use lower bearing opening to gain
access to upper bearing track.
33.If worn, pitted or damaged, renew housing.
34.Fit upper and lower bearing tracks into swivel
bearing housing.
CAUTION: Ensure bearing tracks are fitted
square or damage could occur.
35.With seal lips trailing, fit swivel housing inner oil
seal into rear of housing. Grease seal lips.Fit swivel pin housing
36.Coat swivel bearing housing to axle casing bolts
with Loctite 270 or equivalent.
37.Coat both sides of joint washer with a sealing
compound. Position swivel bearing housing to
axle mating face.
38.Place retaining plate, joint washer and oil seal
over axle flange ready for assembly.
39.Fit swivel bearing housing to axle flange with
seven bolts. Tighten to
73 Nm.
40.Grease and fit upper and lower swivel pin taper
roller bearings.
41.Position swivel pin housing over swivel bearing
housing.
42.Coat joint washer both sides with sealing
compound and position on lower swivel pin.
43.Loosely fit brake shield bracket plus lower swivel
pin with lug outboard to swivel pin housing.
44.Loosely fit top swivel pin plus existing shims and
brake hose bracket to swivel pin housing.
45.Apply Loctite 270 or equivalent to lower swivel
pin bolts. Tighten to
78 Nmbend over lock
tabs.
46.Tighten top swivel pin bolts to
78 Nm.

54FRONT AXLE AND FINAL DRIVE
6
OVERHAUL Swivel assembly components
1. Swivel pin housing
2. Top swivel pin and brake hose bracket
3. Upper and lower swivel pin bearings
4. Shim
5. Retaining plate and washer
6. Oil seal
7. Joint washer
8. Swivel bearing housing
9. Joint washer
10. Lower swivel pin
11. Mudshield bracket
12. Swivel housing inner oil sealCheck and adjust preload on bearings
NOTE: Swivel housing oil seal and axle
should not be fitted.
47.Attach a spring balance to ball joint bore and pull
balance to determine effort required to turn
swivel pin housing.
Resistance, once initial inertia has been
overcome, should be1.16 to 1.46 kg.Adjust by
removing or adding shims to top swivel pin.
48.When setting is correct remove top swivel bolts,
apply Loctite 270 or equivalent. Refit to
78 Nm,
and bend over lock tabs.
49.Apply recommended grease between lips of
swivel oil seal.
50.Fit oil seal, joint washer and retaining plate with
seven bolts and spring washers to
11 Nm.
51.Fit tie rod and drag link and secure with new
cotter pins. Tighten to
40 Nm.
52.Fit brake disc shield.
53.Loosely fit lock stop bolt and nut.
54.Apply a recommended grease between lips of
swivel housing oil seal.
55.Secure oil seal with retaining plate and securing
bolts. Tighten to
11 Nm.
56.Fit track-rod and drag link and secure with new
cotter pins.
57.Loosely fit lock stop bolt for later adjustment.
58.Fit brake disc shield.

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.

54FRONT AXLE AND FINAL DRIVE
10
OVERHAUL
40.With seal lips trailing press axle shaft oil seal
flush into rear of housing. Grease lips.
41.Fit new thrust washers and bearing into top
swivel pin bush.
42.Hang swivel pin bearing housing oil seal and
retainer plate over back of housing. Ensure they
are in correct assembly order.
43.Fit a new joint washer and secure swivel pin
bearing housing to axle. Starting with top fixing
dowel bolt. Tighten to
72Nm.
Fit swivel pin housing
44.Grease and fit lower swivel pin bearing to
bearing housing.
45.Place swivel pin housing in position over swivel
pin bearing housing.
46.Using a new joint washer, fit lower swivel pin
with lip outboard. Do not secure with screws at
this stage.
47.Fit a new sensor bush and new oil seal, lip side
leading to top swivel pin.
48.Lubricate with a recommended oil and fit top
swivel pin with existing shims.
49.Coat threads of top swivel pin bolts with Loctite
542. Fit bolts and jump hose bracket (do not
tighten).50.Coat threads of lower swivel pin screws with
Loctite 270 and fit, together with damper and
shield bracket. Tighten to
25 Nm.
51.Tighten top swivel pin and brake jump hose
bracket securing bolts to
65 Nm.
Check and adjust preload on bearings
52.The preload on bearings to be0,25 to 0,30 mm,
withoutswivel housing oil seal and axle fitted,
and reading from centre of swivel pin. The
torque required to turn swivel assembly from
lock to lock to be
2.0 to 2.8 Nm.Adjust by
removing or adding shims as necessary.
53.To take a reading use special tool LRT-57-024
torque test adaptor, with a torque wrench and
extension as shown.
54.Apply a recommended grease between lips of
swivel housing oil seal.
55.Secure oil seal with retaining plate and securing
bolts. Tighten to
11Nm.
56.Fit track-rod and drag link and secure with new
cotter pins.
57.Loosely fit lock stop bolt for later adjustment.
58.Fit brake disc shield.

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
3
DESCRIPTION AND OPERATION Steering column components
1. Upper shroud
2. Column harness
3. Cruise control switch (if fitted)
4. Steering wheel and nut
5. Rotary coupler
6. Column switch
7. Shear bolts
8. Switch saddle
9. Upper steering column
10. Universal joint
11. Universal joint bolt
12. Steering column lock assembly13. Lower shroud
14. Column lock/ignition
15. Air bag mounting bracket (if fitted)
16. Air bag module
17. Steering pad (non-airbag)
18. Lower shaft
19. Rubber coupling
20. Compression joint
21. Universal joint
22. Universal joint bolt

57STEERING
4
DESCRIPTION AND OPERATION
Power steering box components
1. Housing complete with sector shaft bearings
2. Cover plate complete with bearing
3. Sector shaft
4. Hydraulic piston/rack
5. Worm/valve and torsion bar assembly
6. Shims for centralizing worm/valve
7. Ball race (2)
8. 'Teflon' seals for valve sleeve (3)
9. Bearing adjuster, locknut and seal
10. Worm shaft pressure seal, circlip and dirt
excluder11. 'Teflon' and rubber seal for piston
12. End cover seal and snap ring
13. Adjustment components for piston/rack
14. Hydraulic pipe
15. Bleed screw
16. Sector shaft adjustment lock nut with seal
17. Cover plate bolts (4)
18. Cover plate seal
19. Seal, washer and backup seal
20. Circlip and dust cover

57STEERING
6
DESCRIPTION AND OPERATION Demand for assistance (Valve misaligned)
When the steering wheel and input shaft is turned,
steering resistance transmitted to the worm causes
the torsion bar to be twisted and the valve ports to be
misaligned for a right or left turn. The misalignment of
the valve ports directs all fluid pressure A to one side
of the piston only and allows displaced fluid B on the
other side.When demanding maximum assistance, any
excessive fluid output from the pump due to high
pump speed, will circulate through the regulator valve
located in the pump unit, causing the temperature of
the fluid and the pump to rise rapidly.
To avoid excessive fluid temperatures which could
damage the oil seals, the steering must not be held on
full lock for more that 30 seconds in one minute.
Only when the steering wheel and the demand for
assistance is released, will the torsion bar return the
valve to neutral, allowing the fluid to circulate through
the reservoir where it is cooled.
In the unlikely event of mechanical failure of the
torsion bar, a coarse splined connection (7) between
the input shaft and worm, ensures steering control is
maintained sufficient to allow the vehicle to be
recovered.
Rotary valve misaligned

STEERING
1
FAULT DIAGNOSIS INSUFFICIENT POWER ASSISTANCE
1.Is fluid level correct?
YES - go to 3.
NO - Fill/bleed sytem
2.Is problem a leak?
YES - Diagnose.
See Power Steering Fluid
Leaks
NO - continue
3.Is drive belt tension correct?
YES - go to 5.
NO - retension.
See ENGINE, Repair, Drive
Belt
4.Is problem resolved?
YES - end
NO - continue
5.Carry out pressure test at idle and 1000 rev/min.
See Power Steering System - Test
6.Is correct pressure achieved?
YES - steering box defective
Not at any speed go to 9.
Not at idle go to 7.
7.Is idle speed correct?
YES- Goto8.
NO - Correct idle speed -
If 3.9
See ENGINE TUNING DATA,
Information, Engine 3.9 V8i
If TdiSee ENGINE TUNING DATA,
Information, 300 Tdi Engine
If MpiSee ENGINE TUNING DATA,
Information, Engine - Mpi - 2.0 Litre
8.Is problem resolved?
YES - end
NO - go to 9.
9.Bypass steering box using adaptor tap
LRT-57-001
10.Is correct pressure obtained?
YES - defective steering box
NO - defective steering pump
CAUTION: Do not hold steering wheel on
full lock for more than 30 seconds in any
one minute to avoid overheating fluid and
possibly damaging seals.
NOTE: 1. Excessive pressure in the
system is almost always caused by a
faulty relief valve in the PAS pump.
NOTE: 2. Insufficient pressure in the
system is usually caused by low fluid level
or PAS pump drive belt slip, or one of the
following: PAS system leaks, faulty PAS pump
relief valve, fault in steering box valve and worm
assembly, leak at piston in steering box, worn
components in PAS pump or box.