LAND ROVER DISCOVERY 1995 Workshop Manual

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.

54FRONT AXLE AND FINAL DRIVE
4
REPAIR Refit
11.Clean stub axle and drive shaft and fit hub
assembly to axle.
12.Fit spacing washer.
13.Fit hub adjusting nut. Tighten to
61 Nm.
14.Back off adjusting nut 90°. Tighten to4 Nm.
This will give the required hub end float of
0,010mm
15.Fit a new lock washer.
16.Fit locknut. Tighten to61 Nm.
17.Tab over lock washer to secure adjusting nut
and locknut.
18.Fit a new joint washer to driving member and fit
member to hub and secure with five bolts.
Tighten to
65 Nm.
19.Fit original drive shaft shim and secure with a
circlip.
20.To check drive shaft end play mount a dial
gauge using bracket LRT-99-503 and rest pin in
a loaded condition on end of drive shaft.
21.Fit a suitable bolt to threaded end of drive shaft.
Move drive shaft in and out noting dial gauge
reading. End play should be between0,08 to
0,25 mm.
22.If end play requires adjustment, remove circlip,
measure shim thickness and fit an appropriate
shim to give required end-play.
23.Remove bolt from drive shaft, fit circlip and dust
cap.
24.Fit brake caliper. Tighten to
82 Nm.
25.Bleed brake system.See BRAKES, Repair,
Brake System Bleed
26.Fit road wheel, remove axle stands and tighten
road wheel nuts to
126 Nm.
27.Operate footbrake to locate brake pads before
taking vehicle on road.

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.

54FRONT AXLE AND FINAL DRIVE
2
OVERHAUL 9.With lip side leading fit new seal to hub using
special tool LST 137 seal replacer and drift 18G
134. Drive in seal flush with rear face of hub.
Apply grease between seal lips.
10.Fit brake disc to hub, lining up to marks made
during dismantling. apllying Loctite 270, fit five
retaining bolts. Tighten to
73 Nm.
11.Grease and fit outer bearing to hub.
12.Fit front hub assembly.
See Repair, Front Hub
Assembly

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.

54FRONT AXLE AND FINAL DRIVE
4
OVERHAUL 12.Examine all components in particular inner and
outer track, cage balls and bearing surfaces for
damage and excessive wear.
13.Maximum acceptable end-float on assembled
joint 0,64mm. Renew if worn or damaged.
Lubricate with a recommended oil during
assembly.
Fit constant velocity joint to axle
14.Fit collar and a new circlip.
15.Engage constant velocity joint on axle shaft
splines and using a soft mallet, drive joint in fully.
Renew stub axle,thrust ring, oil seal and bearing
16.Drill and chisel off thrust ring taking care to avoid
damaging stub axle.
17.Remove bearing and oil seal using special tool
LRT-37-004 and slide hammer LRT-99-004.
Ensure lip of tool locates behind bearing to to
drive it out.
18.Repeat instruction for removal of oil seal.
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.

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
8
OVERHAUL 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.
12.Examine all components in particular inner and
outer track, cage balls and bearing surfaces for
damage and excessive wear.
13.Maximum acceptable end-float on assembled
joint 0,64mm. Renew if worn or damaged.
Lubricate with a recommended oil during
assembly.
Fit constant velocity joint to axle
14.Fit collar and a new circlip.
15.Engage constant velocity joint on axle shaft
splines and using a soft mallet, drive joint in fully.
Renew stub axle,thrust ring, oil seal and bearing
16.Drill and chisel off thrust ring taking care to avoid
damaging stub axle.
17.Remove bearing and oil seal using special tool
LRT-37-004 and slide hammer LRT-99-004.
Ensure lip of tool locates behind bearing to to
drive it out.
18.Repeat instruction for removal of oil seal.