suspension LAND ROVER DISCOVERY 1995 User Guide

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
1
REPAIR FRONT AXLE ASSEMBLY
Service repair no - 54.15.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
axle when lowering or repositioning axle.
1.Support chassis front.
2.Remove road wheels.
3.Support axle weight with hydraulic jack.
4.Remove radius arms to chassis frame nuts.
5.Disconnect steering damper from track rod.
Using a extractor remove track rod links from
swivel pin arms.
6.Remove four nuts and bolts securing radius
arms to axle bracket.
7.Remove radius arms.
8.Remove bolts securing brake hose brackets.
Refit bolts to prevent oil leakage.
9.Remove ABS sensor, if applicable.
10.Remove bolts from brake calipers and tie to one
side.
11.Remove nuts and washers securing shock
absorbers to axle.
12.Disconnect drag link from swivel pin housing
arm.
13.Remove two nuts and bolts securing panhard
rod to axle bracket. Lift rod clear of axle.
14.Mark for reassembly drive shaft flanges.
Remove four nuts and bolts, tie propeller shaft to
one side.
15.Lower axle assembly and remove road springs.
16.Disconnect anti-roll[sway] bar link.
See FRONT
SUSPENSION, Repair, Anti-Roll[Sway] Bar
Ball Joint Links
17.Remove axle assembly.
Refit
18.Position axle under vehicle, supporting left side
of axle.
19.Reverse removal procedure.
20.Tighten propeller shaft bolts to
47 Nm.
21.Tighten panhard rod to axle bracket to88 Nm.
22.Tighten drag link to hub arm to40 Nm.
23.Tighten upper swivel pin bolts.See
Specifications, torque, Torque Values
24.Tighten radius arms to axle bolts to197 Nm.
25.Tighten radius arms to chassis side member
nuts to
197 Nm.
26.Tighten track rod end to40 Nm.
Fit new split [cotter] pin.

STEERING
3
FAULT DIAGNOSIS STEERING DAMPER
The power steering system, as well as reducing the
effort required to manoeuvre the vehicle when
parking, also helps to dampen any deflections of the
road wheels, being transmitted back to the steering
wheel.
When operating the vehicle off road, the road wheels
are often deflected by ruts and boulders causing the
steering wheel to turn left and right. This phenomenon
is known as 'steering kickback'. To subdue the effects
of 'steering kickback', a hydraulic damper is fitted in
the steering linkage between the track rod and the
differential casing. The damper, which offers the same
resistance in extension and compression, is sealed for
life.
Steering damper check
Check the condition operation of the hydraulic
steering damper as follows:
Check procedure
1.Inspect damper for casing damage or leaks.
2.Clamp one end of the damper horizontally in a
vice using soft jaws. Compress and extend the
unit by hand. Resistance should be equal in both
directions.
3.If it is felt that the unit is outside acceptable
limits, fit a new steering damperSTEERING FAULTS
Symptom:-
Excessive kickback through steering wheel - when
driven on rough terrain.
1.Is the steering damper in good working order?
See Steering Damper
NO - Renew unit.See Repair, Steering
Damper
YES - Continue.
2.Is there any looseness or free play in the
steering ball joints and linkage?
YES -
See Steering Linkage Inspect
NO - Continue.
3.Is there any looseness or worn bushes in front
suspension?
YES -
See FRONT SUSPENSION, Repair,
Radius Arm
NOTE: When replacing suspension bushes
ALL bushes and fixings must be replaced.
NO - Continue.
4.Is the steering exceptionally light/sensitive when
driven on good road surface?
YES - See fault symptom -Steering
excessively light/sensitive and
freeplay at steering wheel.
NO - Suspect axle swivel resistance.
5.Check the resistance of the axle swivels.
See
FRONT AXLE AND FINAL DRIVE, Overhaul,
Front Stub Axle, Constant Velocity Joint and
Swivel Pin Housing Non ABS See FRONT
AXLE AND FINAL DRIVE, Overhaul, Front
Stub Axle, Constant Velocity Joint and
Swivel Pin Housing ABS

STEERING
5
FAULT DIAGNOSIS Symptom :-
Steering excessively light/sensitive. Excessive
freeplay at steering wheel.
1.Are steering box adjustments correct?
NO -
See Adjustment, Power Steering Box
WARNING: Adjustments of steering box
should not be required while in warranty
period. If box is within warranty, it must be
returned to manufacturer. No attempt must be
made to introduce backlash.
YES - Suspect worn panhard rod or radius arm
bushes Check condition of ball joints and
the lower steering column shaft universal
joints for wear.
See Repair, Lower
Steering Shaft and Universal Joints
Symptom :-
Steering vibration, road wheel shimmy - wobble.
Vibration through the steering linkage powerful
enough to induce high frequency oscillation of the
steering wheel, is generally caused by out of balance
road wheels. However there are a number of other
possible causes of this symptom which if severe, may
be described as shimmy or wobble. Regardless of the
terminology used by the owner/driver to describe the
symptoms, the following diagnostic checks should be
carried out in the order presented.
1.Check the tyres and balance of the road wheels.
See GENERAL SPECIFICATION DATA,
Information, Wheels and Tyres See
WHEELS AND TYRES, Fault diagnosis, Fault
- Symptoms See WHEELS AND TYRES,
Repair, Wheel Balancing
2.Check the steering hydraulic damper function.
See Steering Damper
3.Check steering column universal joints for wear
and correct alignment.
See Repair, Lower
Steering Shaft and Universal Joints
4.Check steering linkage ball joints for wear,
correct alignment and security, including steering
box and tie rod.
See Steering Linkage Inspect
5.Check all front suspension rubbers for wear.
Check all fixing torques, including radius arm
bushes, panhard rod and anti-roll [sway] bar.
See FRONT SUSPENSION, Repair, Panhard
Rod See FRONT SUSPENSION, Repair,
Radius Arm See FRONT SUSPENSION,
Repair, Anti-Roll[Sway] Bar Assembly See
FRONT SUSPENSION, Repair, Front Shock
Absorber
6.Fit new radius arm bushes using NTC 6860. Fit
harmonic damper if vehicle has air suspension.
Fit new nuts, bolts and washers.
7. Coil spring vehicles only- If problem persists
fit damper kit STC 241 (2 off front) and STC
1474 (2 off rear). Road test vehicle.
8.Check the power steering box adjustments and
operation.
See Overhaul, Power Steering Box
9.Check the hub bearing end floats and determine
the condition of the hub bearings. As applicable.
See FRONT AXLE AND FINAL DRIVE, Repair,
Front Hub Assembly
10.Check the resistance and condition of the
swivels.
See FRONT AXLE AND FINAL
DRIVE, Description and operation,
Description
If problem is not diagnosed: Repeat
checks starting at 1.
11.Carry out a full steering geometry check.
See
INTRODUCTION, Information, Steering

57STEERING
6
FAULT DIAGNOSIS STEERING STABILITY AND VEER UNDER
BRAKING
Possible cause:
Incorrectly set, swivel pin bearing preload. There are
three different settings for these bearings dependant
on model year and if fitted with ABS brakes.
Remedy.
1.Establish model year of vehicle.
2.If fitted with or without antilock brakes.
3.Follow instructions to overhaul front stub axle,
constant velocity joint and swivel pin non ABS,
or with ABS as appropriate.
See FRONT AXLE AND FINAL DRIVE,
Overhaul, Front Stub Axle, Constant Velocity
Joint and Swivel Pin Housing Non ABS See
FRONT AXLE AND FINAL DRIVE, Overhaul,
Front Stub Axle, Constant Velocity Joint and
Swivel Pin Housing ABS
1. GENERAL STEERING
1.Carry out visual and safety checks.
See Visual
and Safety Checks
2.Road test vehicle.See Road Test Procedure
3.Is problem resolved?
YES - end
NO - continue
4.Is problem stiff steering?
YES -
See Stiff Steering Checklist
NO- Goto6.
5.Is problem resolved?
YES - end
NO - go to 8.
6.Is problem steering niggle ?
YES - Replace radius arm bushes, arm and
axle.
See FRONT SUSPENSION,
Repair, Radius Arm
NO - go to 8.
7.Is problem resolved?
YES - end
NO - continue.
8.Centralise steering box.
See Adjustment,
Centralise Steering Box
9.Is problem resolved?
YES - end
NO - continue.
10.Check, adjust if necessary, steering geometry.
11.Is problem resolved?
YES - end
NO - continue.
12.Categorise the remaining problems into one or
more of the following descriptions:
See 2. Steering Veer
See 3. Veer Under Braking
See 4. Directional Stability

STEERING
9
FAULT DIAGNOSIS POWER STEERING SYSTEM - EXCESSIVE NOISE
1.Is fluid level correct?
YES - go to 3.
NO - Refill or drain to correct level. Bleed
system, check for leaks.
See Repair,
Power Steering System - Bleed
2.Is problem resolved?
YES - end
NO - continue.
3.Is pressure hose from pump to box touching
body in a hard foul condition?
YES - reroute hose away from body.
NO - go to 5.
4.Does noise remain?
YES - continue.
NO - end.
5.Is noise a whistle or hiss on full lock?
YES - noise is not a fault unless excessive.
Compare with other vehicles
NO - go to 8.
6.Is noise excessive?
YES - continue.
NO - end.
7.Change steering box and/or pump.
8.Is noise a squeal on full lock?
YES - check/reset drive belt tension.
See
ENGINE, Repair, Drive Belt
NO - go to 10.
9.Does squeal remain?
YES - drive belt contaminated, change belt.
NO - end.
10.Is noise a continuous moan?
YES - bleed PAS system.
See Repair, Power
Steering System - Bleed
NO - go to 13.
11.Does moan remain?
YES - do figure 8 manoeuvres.
NO - end.
12.Does moan remain?
YES - continue
NO - end.13.Is noise an intermittent "grunt"?
YES -
See Power Steering System - Grunt
NO - continue.
14.Is it a clunking noise?
YES - reset drive belt tension.
See ENGINE,
Repair, Drive Belt
NO - contact local technical office.
15.Does noise remain?
YES - Suspect suspension or drive train.
NO - end.
POWER STEERING SYSTEM - GRUNT
Steering box grunts intermittently when turning
from lock to lock:
1.Is fluid level correct?
YES - go to 3.
NO - refill or drain to correct level. Bleed
system, check for leaks.
See Repair,
Power Steering System - Bleed
2.Does grunt remain?
YES - continue
NO - end.
3.Is correct low pressure hose ANR 3152, steering
box to reservoir fitted?
YES - go to 5.
NO - Fit correct hose.
4.Does grunt remain?
YES - continue
NO - end.
5.Purge box by doing figure 8 manoeuvres e.g. on
car park, followed by 10 minutes normal road
use.
6.Does grunt remain?
YES - Contact local technical office
NO - end.

57STEERING
12
FAULT DIAGNOSIS Steering column alignment
1.Place vehicle on level ground. Measure the
angle of lower steering shaft using a Pernumeter
placed on the shaft between the universal joints.
The angle should measure a minimum of 12Ê.
2.If necessary, realign the shaft. Release the five
fixings securing the steering column. Position
column as required. Tighten the fixings evenly,
27 Nm.
3.Loosen the three screws securing lower steering
column shroud to upper shroud ensure lower
shroud is clipped to upper shroud. Reposition
shroud, tighten screws.
4.Recheck steering column angle.
Steering box adjustment
1.Check steering box adjustment.
See
Adjustment, Power Steering Box
Steering damper check
1.Check condition of steering damper
See
Steering Damper
VISUAL CHECK AND BASIC ADJUSTMENTS
NOTE: It is important that the following
instructions are carried out in the
sequence shown and the results recorded.
1.Road springs - check that road springs are
correctly seated and are to correct specification
for vehicle. For spring specification.
See
GENERAL SPECIFICATION DATA,
Information, Road Springs Data
2.Ride height - measure trim height from wheel
centre to wheelarch eyebrow. Record results on
data sheet.
3.Check/top up power steering fluid
See Repair,
Power Steering Fluid Reservoir
4.Check tension and condition of drive belt.See
ENGINE, Repair, Drive Belt
5.Track rod/drag link - check condition of track rod,
drag link and ball joints.
See Repair, Drag Link
and Drag Link Ends
If either component is damaged, check operation
of steering damper and steering box for
smoothness. Replace all damaged or worn
components that impair the operation of the
steering system.
6.Suspension bushes - examine all steering and
suspension bushes for signs of wear and
deterioration. Also check all fixings for torque
relaxation. Tighten to correct torque value.
See
FRONT SUSPENSION, Specifications, torque,
Torque Values
7.Oil leaks - check front and rear axle hubs for
leak and repair as necessary.
8.Brake system - check brake system for leaks,
pipe condition, pad wear/contamination, disc
wear/condition and ABS sensors for correct
fitting.
9.Hub end float - check movement in the hubs by
rocking the wheels.
10.Check front wheel alignment. Vehicles displaying
a tendency to veer more than considered
allowable, it is permissible to set the front track
to parallel.
11.Having completed all the above checks and
adjustments, road test vehicle.
See Road Test
Procedure
Attempting to reproduce the symptoms
established earlier. If symptoms still exist refer to
relevant Diagnostic Chart.

FRONT SUSPENSION
1
DESCRIPTION AND OPERATION INTRODUCTION
Suspension design is a major factor in determining the comfort, safety and performance of any vehicle, but is
particularly significant to 4 wheel drive cross country vehicles. The ideal suspension must allow maximum wheel
travel and axle articulation, and provide good ground clearance without loss of traction or directional stability.
A well designed beam axle layout can embrace all of these qualities and also has the inherent advantage (over
independent systems) of no variation in wheel track or camber angle.
Suspension comparison
1. Beam axle system
2. Independent system

60FRONT SUSPENSION
2
DESCRIPTION AND OPERATION AXLE LOCATION
The front axle is controlled longitudinally, by two forged steel radius arms and transversely by a panhard rod.
Front axle suspension
1. Panhard rod - transverse location
2. Radius arms - longitudinal location
3. Coil springs
4. Shock absorber
Long travel coil springs and hydraulic shock absorbers, provide the springing for each wheel.

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.