tow LAND ROVER DISCOVERY 1995 Owner's Manual

FRONT AXLE AND FINAL DRIVE
9
OVERHAUL 19.Lubricate seal and lip with EP90 oil and with
cavity side leading press in a new oil seal using
special tool LRT-54-004.
20.Using special tool LRT-54-005, fit bearing with
its part number visible when fitted, and flush with
end face of stub axle.
21.Press fit a new thrust ring onto stub axle.
Swivel pin housing assembly
22.Remove brake disc shield bracket.
23.Disconnect track-rod end ball joint from housing.
24.Disconnect drag-link ball joint.
25.Disconnect jump hoses from brake jump hose
bracket.
26.Remove ABS brake sensor.
27.Remove six bolts securing oil seal and retaining
plate to swivel pin housing. Prise seal from
swivel pin housing.
NOTE: Oil seal and retaining plate cannot
be removed until swivel pin bearing
housing is removed.
28.Remove two screws securing brake
damper/shield bracket and lower swivel pin to
housing.
29.Withdraw lower swivel pin and joint washer by
tapping protruding lug.
30.Remove top swivel pin retaining bolts complete
with brake jump hose bracket.
31.Remove top swivel pin and shims.
32.Remove swivel pin housing while retrieving
lower taper bearing.
Swivel pin bearing housing
33.Remove seven bolts securing swivel pin bearing
housing to axle case.
34.Remove and discard oil seal and joint washer.
35.Remove lower swivel pin bearing track.
36.Remove top swivel pin bush housing assembly.
Discard two thrust washers and bearing.
37.If worn, pitted or damaged, renew swivel pin
bearing housing.
38.Fit a new lower swivel pin bearing track.
39.Fit a new bush and bush housing. Ensure
relieved lip of bush housing faces towards rear,
as shown.

STEERING
1
DESCRIPTION AND OPERATION DESCRIPTION
The power assisted steering system incorporates a
compression joint in the lower shaft, designed to
collapse on impact and for certain countries, an air
bag located in the centre of the steering wheel.
The mis-alignment of the upper steering column with
the steering box and the inclusion of two universal
joints and a compression joint in the lower shaft, is
also designed to prevent frontal impact moving the
column toward the driver.
The steering box is located behind the first cross
member of the chassis and is connected to the road
wheels by the drag link and track rod. An hydraulic
damper absorbs shocks in the steering, caused by
road wheel deflections when operating on rough
terrain.Power steering system
The power steering system comprises a hydraulic
pump which is belt driven from the engine and
supplied with fluid from a reservoir that also acts as a
cooler.
The steering box houses a self neutralizing rotary
valve which is part of the worm/valve assy and a
hydraulic piston/rack to assist the mechanical
operation.
The rotary valve which is operated by movement of
the steering wheel, directs fluid pressure to the
appropriate side of the hydraulic piston/rack to provide
assistance.
Power steering system
1. Hydraulic pump
2. Fluid reservoir
3. Steering box
4. Upper column
5. Universal joints
6. Lower shaft
7. Compression joint
8. Drag link

57STEERING
8
FAULT DIAGNOSIS 4. DIRECTIONAL STABILITY
From 1. GENERAL STEERING:
1.Is directional stability concern when vehicle is
towing?
YES - Check towing/vehicle loading parameters
in Owner's Handbook.
NO - go to 3.
2.Is problem resolved?
YES - end
NO - continue.
3.Check condition of rear trailing link/chassis
bushes.
4.Is problem resolved?
YES - end
NO - continue.
5.Check condition of front and rear shock
absorbers. If in doubt change units in pairs, side
to side.
6.Is problem resolved?
YES - end
NO - continue.
7.Check steering damper.
See Steering Damper
8.Is problem resolved?
YES - end
NO - continue.
9.Check wheel balance
10.Is problem resolved?
YES - end
NO - contact local technical office.POWER STEERING FLUID LEAKS
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.Are hoses or joints leaking? Check on full lock
with engine at 2000 rev/min.
YES - loosen and retorque joints.
NO - go to 6.
4.Does leak remain?
YES - change PAS pipe.
NO - end.
5.Does leak remain?
YES - suspect seal in component. Check and
replace as necessary.
NO - end.
6.Is oil escaping from filler cap?
YES - bleed system.
See Repair, Power
Steering System - Bleed
NO - go to 8.
7.Is oil still escaping from filler cap?
YES - go back to 1.
NO - end.
8.Is oil leaking from PAS pump?
YES - go to 10.
NO - continue.
9.Is oil leaking from PAS box?
YES - go to 10.
NO - end.
10.Clean unit, add tracer dye to system. Retest
11.Is oil still leaking?
YES - establish leak point. Repair or replace
unit as necessary.
NO - end.

57STEERING
10
FAULT DIAGNOSIS VISUAL AND SAFETY CHECKS
WARNING: Before taking vehicle out on
the public highway for road test, it is
important that the following basic visual
checks are carried out to ensure that the vehicle
complies with legal requirements.
Tyres and wheel rims
1.Check and adjust tyre pressures.
See
GENERAL SPECIFICATION DATA,
Information, Tyre Pressures
Note that this information refers to standard tyres
fitted as original equipment.
2.Check condition of tyres. Inspect for signs of
uneven wear, damage and feathering. Check
tread depth.
3.Ensure that the tyre make, type and general
condition are common across each axle.
4.Check wheel rims for signs of damage and
excessive run out.
5.Carry out road test.
See Road Test Procedure
ROAD TEST PROCEDURE
General steering/handling problems can usually be
classified into one of the categories listed and ARE
GENERALLY RELATED TO THE AGE, CONDITION
AND USE OF THE VEHICLE.
WARNING: Ensure that all road tests are
conducted by suitably qualified drivers in
a safe and legal manner, and where local
traffic conditions allow.
1.Carry out visual and safety checks.
See Visual
and Safety Checks
Confirm general nature of complaint with customer,
simulating where possible the conditions under which
the problem occurs. Carry out following road test
procedure to establish the problem.2.Steering load assessment - drive at 16 km/h (10
mph). Put 90°turn input into steering wheel,
check self centering. The self centering should
be equal on each lock BUT not necessarily
return to exactly straight ahead without
assistance from the driver.
3.Steering assessment - drive at 64 km/h (40 mph)
on a staight FLAT road (no camber), check for
steering veer. The vehicle should follow a
straight path with NO tendency to follow a
curved path. If vehicle veers towards the kerb,
vehicle may be 'camber sensitive'. A small
amount of veer in direction of camber is
acceptable.
4.Directional stability assessment - drive at 112
km/h (70 mph) or maximum legal speed on a
straight flat road. Carry out a normal lane
change. Vehicle should quickly settle into a new
straight path.
5.Braking assessment (medium effort) - drive at 96
km/h (60 mph) on a straight flat road. Apply
steady medium braking effort, noting any
tendency to veer. Carry out brake test three
times, if a veer is consistently noted carry out a
braking efficiency test on a rolling road.
6.Braking assessment (full effort) - drive at 96
km/h (60 mph) on a straight flat road. Apply full
braking effort, noting any tendency to veer. Carry
out brake test three times, if a veer is
consistently noted carry out a braking efficiency
test on a rolling road.
If the symptom described by the customer is stiff
steering or steering niggle, carry out stiff steering
procedure.
See Stiff Steering Checklist
If not proceed with basic checks and adjustments.
See Visual Check and Basic Adjustments

STEERING
7
OVERHAUL Fitting sector shaft cover
73.Fit new sealing ring to cover.
74.Align cover with casing.
75.Screw cover assembly fully on to sector shaft
adjuster screw.
76.If necessary back off sector shaft adjuster screw.
Tap cover in place to allow cover to joint fully
with casing.
NOTE: Before tightening fixings, rotate
input shaft to ensure sector shaft roller is
free to move in valve worm. If initial
resistance is left, turn adjuster screw
approximately two turns in a clockwise direction.
77.Fit cover bolts. Tighten to
75 Nm.
Fitting cylinder cover
78.Fit new square section seal to cover.
79.Remove slave bolt fitted at instruction 68. Press
cover into cylinder just to clear retainer ring
groove.
80.Fit retaining ring to groove with one end of ring
positioned 12 mm from extractor hole.
Adjusting sector shaft
NOTE: Refit drop arm and tighten nut
sufficiently to ensure that no backlash
exists between drop arm and sector shaft.
81.To set worm on centre, rotate input shaft to full
inner-lock (full right lock for a left hand drive
vehicle, full left lock for a right hand drive
vehicle). Rotate input shaft back towards centre
two full turns.
82.The box is now on centre and can be adjusted.

57STEERING
8
OVERHAUL 83.Hold input shaft and rock drop arm to establish
backlash is present. Continue rocking and slowly
turn sector shaft adjusting screw clockwise.
Continue rotating adjuster screw until backlash
has almost been eliminated.
84.Refit locknut and tighten.
NOTE: It is important steering box is
centralised before any adjustments are
made.
85.Check maximum rolling torque one and a quarter
turns either side of centre position, using a
torque wrench and spline socket LRT-57-025.
Rotate adjuster screw to obtain across centre
torque of 0.34 Nm plus torque figure at one and
a quarter turns. Tighten adjuster locknut to
60
Nm.
Adjusting rack adjuster.
86.Turn in rack adjuster to increase figure
measured in instruction 85. by 0.23 - 0.34 Nm.
The final figure may be less, but must not
exceed 1.35 Nm.
87.Lock rack adjuster in position with grub screw.
Tighten to
5 Nm.
Torque peak check
With input shaft rotated from lock to lock, rolling
torque figures should be greatest across centre
position and equally disposed about centre position.
The condition depends on value of shimming fitted
between valve and worm assembly inner bearing cup
and casing. The original shim washer value will give
correct torque peak position unless major components
have been replaced.Procedure
88.With input coupling shaft toward the operator,
turn shaft fully counter-clockwise.
89.Check torque figures obtained from lock to lock
using torque wrench and spline socket
LRT-57-025.
90.Check also for equal engagement either side of
centre.
Adjustments
91.Note where greatest figures are recorded
relative to steering position.If greatest figures are
not recorded across centre of travel (steering
straight-ahead), adjust as follows:
If torque peak occursbeforecentre position,addto
shim washer value; if torque peak occursaftercentre
position,subtractfrom shim washer value,
refer to
fitting valve and worm assembly
.
Shim washers are available as follows:
0.03mm, 0.07mm, 0.12mm and 0.24mm.
NOTE: Adjustment of 0.07mm to shim
value will move torque peak area by 1/4
turn on the shaft.
CAUTION: When reshimming valve and
worm, extreme caution must be exercised
to prevent seal damage during
reassembly.

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

64REAR SUSPENSION
4
REPAIR ANTI-ROLL[SWAY] BAR ASSEMBLY REAR
Service repair no - 64.35.08.
KEY
1. Anti-roll[sway] bar
2. Rubber bush
3. Strap
4. Nut, bolt, washer5. Nut and washer
6. Ball joint link arm
7. Bolt and washer
8. Castellated nut and cotter pin
Remove
1.Note for reassembly, position of rubber bushes
on anti-roll bar.
2.Remove four nuts, bolts and washers securing
two bush straps.
3.Remove nuts, bolts, washers and rubber bushes
from the ball joint links and remove anti-roll bar.Refit
4.Position rubber bushes on anti-roll bar. Fit joint
towards axle.
5.Fit anti-roll bar with two straps. Ensure ball joint
link arms point down as shown. Loosely fit, bolts,
washers and new nyloc nuts.
6.Fit bolt, washers and rubber bushes. Fit anti-roll
bar to ball joint links. Tighten to
68Nm.
7.Tighten nuts securing straps to30Nm.

BRAKES
7
REPAIR 19.Coat new seals in unused brake fluid. Fit 'L' seal
to plunger.
20.Fit washer followed by recuperating seal. Fit seal
retainer and springs, ensure springs are
correctly seated.
Assembling master cylinder
CAUTION: It is important that following
instructions are carried out precisely,
otherwise damage could be caused to new
seals when inserting plungers into cylinder bore.
Generous amounts of new brake fluid should be
used to lubricate parts during assembly.
21.Fit new swirl tube to bottom of cylinder bore.
22.Lubricate secondary plunger and cylinder bore.
Offer plunger assembly to cylinder until
recuperation seal is resting centrally in mouth of
bore. Gently introduce plunger with a circular
rocking motion, as illustrated. Ensuring that seal
does not become trapped, ease seal into bore
and slowly push plunger down bore in one
continuous movement.
23.Fit new primary plunger assembly using same
method as for secondary plunger.
24.Fit original guide ring to support primary plunger.
25.Coat a new 'O' ring with brake fluid and fit to its
respective groove on outer location surface of
master cylinder.
CAUTION: Do not roll 'O' ring down outer
location surface of master cylinder. It
should be slightly stretched and eased
down cylinder and into its groove. Do not over
stretch seal.
26.Fit new retaining ring on outer surface of master
cylinder ensuring that serrations of ring are
facing mounting flange.
27.Fit two new reservoir seals in respective ports.
28.Fit a new vacuum seal to either primary plunger
or to bottom of transfer housing bore, open face
of seal towards primary plunger.
29.Lubricate vacuum seal with brake fluid. Fit
transfer housing to master cylinder, push
housing fully up to cylinder mounting flange, Do
not adjust transfer housing after fitting.
30.Lubricate new water ingress seal with brake
fluid, Slightly stretch seal and ease down
housing until it is in position between housing
and flange.
31.Roll reservoir into top of master cylinder,
reversing procedure described in instruction 10.
Refit
NOTE: Ensure O ring seal between master
cylinder and servo unit is fitted correctly.
32.Fit master cylinder to servo. Secure in position
with two nuts, plain and spring washers. Tighten
to
26 Nm.
33.Fit brake pipes to master cylinder. Tighten to
15Nm.
34.Top-up master cylinder with correct grade of
brake fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
35.Bleed system.See Brake System Bleed
36.Fit cap, reconnect electrical lead to fluid level
switch. Reconnect battery negative lead.

SUPPLEMENTARY RESTRAINT SYSTEM
5
DESCRIPTION AND OPERATION
7.Do not use electrical test equipment on the
airbag harness or connectors. Tampering with or
disconnecting the harness could result in
accidental firing of the airbag or make the
system inoperative, which may result in serious
injury.
8. An airbag system fault can only be
diagnosed using TestBook.
9.The airbag module contains Sodium Azide which
is poisonous and extremely flammable. Contact
with water, acid or heavy metals may produce
harmful or explosive compounds. Do not
dismantle, incinerate or bring into contact with
electricity.VEHICLE RECOVERY
Towing - airbag not deployed
Normal towing procedures are unlikely to cause an
airbag to deploy. However, as a precaution switch the
ignition off and then disconnect both battery leads.
Disconnect the negative '-' lead first.
Towing - airbag deployed
Once the driver's airbag has been deployed the
vehicle must have a front suspended tow. However,
as a precaution switch the ignition off and then
disconnect both battery leads. Disconnect the
negative '-' lead first.