ABS LAND ROVER DISCOVERY 1995 Service Manual

REAR AXLE AND FINAL DRIVE
1
SPECIFICATIONS, TORQUE AXLE DIFFERENTIAL DATA
Pinion bearing pre-load:
(new bearings) 3 Nm........................................................
(bearings bedded in) 1,5 Nm...............................................
Crown wheel run-out 0,10 mm........................................................
Crown wheel/pinion backlash 0,10 to 0,17 mm...........................................
REAR HUB
Rear hub end float 0,010 mm............................................................
TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
REAR AXLE
Pinion housing to axle case 41.......................................................................
Crown wheel to differential case 58................................................................
Differential bearing cap to pinion housing 90..................................................
Differential drive flange to drive shaft 47.........................................................
Bevel pinion nut 129........................................................................................
Lower link to axle 176......................................................................................
Pivot bracket ball joint to axle 176...................................................................
REAR HUB ABS VEHICLES
Hub driving member to hub 65 *.......................................................................
Brake disc to hub 73 *......................................................................................
Stub axle rear to axle case 65........................................................................
Brake caliper to axle case 82..........................................................................
Disc shield to axle case 11.............................................................................
Sensor ring to brake disc ABS 9....................................................................
* Apply loctite 270 prior to assembly.

REAR AXLE AND FINAL DRIVE
3
SERVICE TOOLS
LRT-54-508 Wrench flange and carrier
RO530105 bearing nuts
REAR HUB
LRT-99-503 Bracket for dial gauge and indicator
RO530106
LRT-54-001 Oil seal replacer non ABS
LST550-5
LRT-99-003 Drift
18G134

51REAR AXLE AND FINAL DRIVE
4
SERVICE TOOLS
LRT-54-002 Hub nut wrench
RO606435A
LRT-54-003 Hub oil seal replacer ABS
LST137
LRT-54-004 Oil seal replacer ABS
LST138

FRONT AXLE AND FINAL DRIVE
1
DESCRIPTION AND OPERATION DESCRIPTION
The welded steel front 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 front wheels via the axle shafts and
constant velocity joints which are totally enclosed in
the spherical and swivel housings.
The front axles fitted with ABS brakes or non ABS
brakes are of the same construction except for
different top swivel pins in the swivel housing and a
sensor on the constant velocity joint.
Front axle - ABS
The front wheels are pivoted on taper roller bearings
19 at the bottom of the swivel housing and a 'Rialco
bush' 25 at the top. The top swivel pin also houses the
ABS pickup (electrical connection) as shown in the
main illustration, J5367.
Front axle - non ABS
The front wheels are pivoted on tape roller bearings at
the top (see insert) and bottom of the swivel housing.
The wheel hubs on all axles are supported by two
taper bearings and driven by drive flanges which are
splined to the one piece, stub shaft/constant velocity
joint.
Lubrication
The differential, swivel pin housing and wheel hubs
are indiviudally lubricated and separated by oil seals 7
and 8 to prevent oil transfer across the axle when the
vehicle is traversing steep inclines. The wheel
bearings are lubricated with grease and the swivel
housing and differential with oil.
Ventilation
Ventilation of the differential is through a plastic pipe 2
which terminates at a high level in the vehicle on both
ABS and non ABS axles. The swivel housings
ventilate through axle shaft oil seals 8 into the
differential and the hub bearings vent via the oil seals
into swivel housing.

54FRONT AXLE AND FINAL DRIVE
2
DESCRIPTION AND OPERATION
Front axle
1. Axle casing
2. Ventilation pipe
3. Axle shaft
4. Wheel studs and hub
5. Stub axle
6. Wheel bearings (2)
7. Inner and outer hub seals
8. Axle shaft seal
9. Hub lock plate, thrust washer and nuts (2)
10. Brake disc
11. Drive flange
12. Shim washer and circlip
13. Dust cap14. Constant velocity joint/shaft
15. Thrust collar for CV joint
16. Roller bearing
17. Spacer
18. Circlip
19. Bottom swivel taper bearing
20. Top and bottom swivel pins
21. Spherical housing, seal and retainer
22. Swivel housing
23. Constant velocity shaft seal
24. ABS pickup (electrical connection)
25. 'Rialco' bush ABS

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.

FRONT AXLE AND FINAL DRIVE
3
REPAIR FRONT HUB ASSEMBLY
Service repair no - 60.25.01.
Remove
1.Loosen front wheel nuts, jack up vehicle and
lower onto axle stands and remove road wheel.
2.Release brake hose clips and remove brake
caliper. Secure to one side.
3.Lever off dust cap.
4.Remove circlip and drive shaft shim from
driveshaft.
5.Remove five bolts and withdraw driving member
and joint washer.
6.Bend back lock washer tabs.
7.Remove locknut and lock washer.
8.Remove hub adjusting nut.
9.Remove spacing washer.
10.Remove hub and brake disc assembly complete
with bearings.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
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
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.