LAND ROVER DISCOVERY 1995 Workshop Manual

STEERING
9
REPAIR LOWER STEERING SHAFT AND UNIVERSAL
JOINTS
Service repair no - 57.40.25
CAUTION: Before removing any parts of
steering linkage, it is imperative that road
wheels are positioned straight ahead.
Then steering wheel removed to prevent rotary
coupler being wound up or damaged.
CAUTION: After refitting steering linkage
parts follow correct procedure to ensure
that road wheels, steering box and
steering wheel are correctly positioned relative to
each other when in straight ahead condition. If
steering wheel requires repositioning, ensure that
drive pegs on rotary coupler are correctly
positioned before steering wheel is replaced.
This ensures drive pegs locate in their holes in
rear of steering wheel.
After final alignment connect rotary coupler,
tighten steering wheel securing nut and fit air bag
module - if fitted or steering wheel trim pad.
Remove
1.Ensure road wheels are straight ahead.
2.Remove pinch bolt securing top universal joint to
steering column.
3.Remove 2 pinch bolts securing lower universal
joint.
4.Move lower shaft up to release lower universal
joint from steering box splines. Remove lower
shaft.
5.Remove universal joint from lower shaft.
NOTE: Do not dismantle upper coupling
joint. Steering shaft, rubber coupling and
top universal joint is only available as an
assembly.
6.Inspect lower universal joint for wear and
excessive play, renew if necessary.
7.Inspect top universal joint and rubber coupling,
renew lower shaft as an assembly if necessary.
8.Inspect universal joints for stiffness, lubricate if
necessary.
NOTE: Prior to fitting a replacement
steering shaft check the following:9.Release stud fasteners securing heat shield (if
fitted).
10.Check that indicator clip coloured red is fully
inserted under head of compression joint bolt.
WARNING: If clip is displaced, no attempt
must be made to drive clip into
engagement, a new shaft assembly must
be fitted.
11.Secure heat shield stud fasteners (if fitted).
Refit
NOTE: Fit universal joints so pinch bolt
holes line up with flat on shaft.
12.Position lower universal joint on shaft.
13.Position shaft assembly onto steering column.
Move assembly up spline to enable lower
universal joint to fit onto steering box splines.
14.Align bolt holes with grooves in splines. Fit pinch
bolts. Tighten to
25 Nm.

57STEERING
10
REPAIR STEERING COLUMN SHROUD
Service repair no - 57.40.29
Remove
1.Disconnect battery negative lead.
2.Remove 3 screws securing shroud.
3.Carefully release upper shroud from lower.
4.Manoeuvre lower shroud clear of steering
column.
Refit
5.Position upper and lower shrouds to steering
column ensuring plastic tags on lower shroud
are correctly located. Clip both halves of shroud
together.
6.Fit and tighten 3 screws.STEERING WHEEL
Service repair no - 57.60.01
CAUTION: Prior to commencing work on
vehicles fitted with an air bag,
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Description and operation,
CAUTION: Before removing any parts of
steering linkage, it is imperative that road
wheels are positioned straight ahead.
Then remove steering wheel to prevent rotary
coupler being wound up or damaged.
CAUTION: After refitting steering linkage
parts follow correct procedure to ensure
that road wheels, steering box and
steering wheel are correctly positioned relative to
each other when in straight ahead condition. If
steering wheel requires repositioning, ensure that
drive pegs on rotary coupler are correctly
positioned before steering wheel is replaced.
This ensures drive pegs locate in their holes in
rear of steering wheel.
After final alignment connect rotary coupler
multiplug, tighten steering wheel securing nut and
fit air bag - if fitted or steering wheel trim pad.

STEERING
11
REPAIR Remove
1.Disconnect battery negative lead.
2.Position road wheels straight ahead so steering
wheel can be correctly re-assembled.
3. Airbag fitted:Remove air bag.
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair, Driver's Airbag Module
4.Remove trim pad from steering wheel,
disconnect Lucars from horn button.
5.Disconnect rotary coupler multiplug.
6.Loosen but do not remove retaining nut.
7.Release steering wheel from taper, remove
retaining nut and washer.
8.Release harness from retaining clip.
9.Withdraw steering wheel whilst at the same time
feeding harness through wheel hub.
CAUTION: Prevent rotation of rotary
coupler once steering wheel is removed.
Secure in position with adhesive tape.
NOTE:Do not carry out further
dismantling if component is removed for
access only.
Refit
10.Recheck road wheels are positioned straight
ahead.
11.Position steering wheel to column, feed harness
through wheel hub.
12.Remove adhesive tape securing rotary coupler.
13.Locate rotary coupler drive pegs and indicator
switch self-cancel pegs in steering wheel hub,
push wheel fully onto taper.
14.Fit steering wheel nut. Tighten to
50 Nm.
15.Connect rotary coupler multiplug.
16.Non airbag module: Fit horn push assembly,
connect Lucars to horn button, secure harness
in clip.
17.Fit airbag module - if fitted.
See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair, Driver's Airbag Module
18.Reconnect battery negative lead.

57STEERING
12
REPAIR UPPER STEERING COLUMN
Service repair no - 57.40.01
NOTE: Steering column assembly is not a
serviceable component.
CAUTION: Before removing any parts of
steering linkage, it is imperative that road
wheels are positioned straight ahead. then
steering wheel removed to prevent rotary coupler
being wound up or damaged.
CAUTION: After refitting steering linkage
parts follow correct procedure to ensure
that road wheels, steering box and
steering wheel are correctly positioned relative to
each other when in straight ahead condition. if
steering wheel requires repositioning, ensure that
drive pegs on rotary coupler are correctly
positioned before steering wheel is replaced.
This ensures drive pegs locate in their holes in
rear of steering wheel.
After final alignment, connect rotary coupler
multiplug, tighten steering wheel securing nut and
fit airbag - if fitted or steering wheel trim pad and
horn push assembly.
Remove
1.Remove steering wheel.
See Steering Wheel
CAUTION: Prevent rotation of rotary
coupler once steering wheel is removed.
Secure in position with adhesive tape.
2.Remove driver's access panel.
3.Remove steering column shroud.
See Steering
Column Shroud
4.Remove rotary coupler.See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair, Rotary Coupler
5.If fitted - remove 4 screws securing knee bolster,
remove knee bolster.
6.Disconnect column switch multiplug.
7.Disconnect ignition switch multiplug from fuse
box.

STEERING
13
REPAIR
8.Disconnect ignition switch main feed multiplug.
9.Remove 4 nuts securing upper column to lower
mounting.
10.Remove 2 nuts securing lower mounting steady
bracket, remove bracket.
11.Remove pinch bolt securing upper column to
universal joint.
12.Remove 2 nuts and washes securing upper
column to upper mounting bracket.13.Carefully manoeuvre upper column out of
footwell, recover rubber boot.
NOTE: Do not carry out further
dismantling if upper column is removed
for access only.
14.Loosen but, do not remove screw securing
column switch assembly, withdraw assembly to
gain access to multiplugs.
15.Disconnect column switch multiplugs, remove
column switch assembly.
16.Disconnect ignition switch multiplug.
17.Remove shear bolts securing steering column
lock, remove lock and saddle; discard shear
bolts.
18.Withdraw bulb holder from column lock shroud.
19.Transfer components to new upper column,
connect multiplug.
NOTE: Do not shear column lock bolts at
this stage.

57STEERING
14
REPAIR Refit
20.Manoeuvre upper column to position in footwell,
ensure splines in column and universal joint are
correctly engaged and rubber boot is fitted.
21.Fit but do not tighten universal joint pinch bolt.
22.Position upper column to upper mounting, fit
washers and nuts, do not tighten nuts.
23.Fit but do not tighten nuts and bolts securing
upper column to lower mounting.
24.Fit lower mounting steady bracket, fit but do not
tighten nuts and bolts.
25.Ensure upper column is aligned to mountings.
26.Tighten all nuts and bolts to
22 Nm.
27.Tighten universal joint pinch bolt to25 Nm.
28.Connect column switch multiplug.
29.Connect ignition switch multiplugs.
30.Fit rotary coupler.
See SUPPLEMENTARY
RESTRAINT SYSTEM, Repair, Rotary
Coupler
31.Fit steering wheel.See Steering Wheel
32.Reconnect battery negative lead.
33.Check steering column lock for correct
operation, tighten shear bolts until heads shear
off.
34.If fitted - position knee bolster, fit and tighten
screws.
35.Fit steering column shroud.
See Steering
Column Shroud
36.Fit driver's access panel.

STEERING
15
REPAIR STEERING COLUMN LOCK ASSEMBLY
Service repair no - 57.40.31
Remove
CAUTION: Before removing any parts of
steering linkage, it is imperative that road
wheels are positioned straight ahead.
Then steering wheel removed to prevent rotary
coupler being wound up or damaged.
CAUTION: After refitting steering linkage
parts follow correct procedure to ensure
that road wheels, steering box and
steering wheel are correctly positioned relative to
each other when in straight ahead condition. If
steering wheel requires repositioning, ensure that
drive pegs on rotary coupler are correctly
positioned before steering wheel is replaced.
This ensures drive pegs locate in their holes in
rear of steering wheel.
After final alignment connect rotary coupler
multiplug, tighten steering wheel securing nut and
fit airbag module - if fitted.
1.Disconnect battery negative lead.
2.Remove steering column shroud.
See Steering
Column Shroud
3.Release turnbuckles, lower driver's access
panel.
4.If fitted, remove 4 screws securing knee pad,
remove bolster.
5.Disconnect ignition switch multiplug from fuse
box.
6.Disconnect ignition switch main feed multiplug.

57STEERING
16
REPAIR
7.Remove bulb holder from steering column lock
shroud.
8.Tap head of shear bolts anti-clockwise to release
them.
9.Remove and discard shear bolts.
10.Detach saddle.
11.Remove steering column lock assembly.
Refit
12.Position steering lock saddle on column, locating
spigot in hole provided.
13.Place lower lock assembly into column.
14.Fit but do not fully tighten new shear bolts.
15.Connect multiplugs.
16.Insert bulb holder into steering column lock
shroud.
17.Reconnect battery negative lead.
18.Check steering column lock for correct
operation, tighten shear bolts until heads shear
off.
19.Fit steering column shroud.
See Steering
Column Shroud
20.If fitted - fit knee bolster, fit and tighten screws.
21.Raise driver's access panel, secure turnbuckles.DROP ARM
Service repair no - 57.50.14
Remove
1.Place vehicle on a hoist, or support front axle on
axle stands.
2.Disconnect drag link ball joint from drop arm,
using extractor LRT-57-018.

STEERING
17
REPAIR 3.Bend back tabs on locking washer and remove
drop arm using extractor LRT-57-012. Loosen
drop arm securing nut, but do not remove before
using extractor.
4.Remove nut, discard locking washer.
Refit
5.Centralise steering box.
See Adjustment,
Centralise Steering Box
6.Fit drop arm, align master splines.
7.Fit a new tab washer and drop arm fixing nut.
Tighten to
176 Nm,bend over tab.
8.Fit drag link. Tighten ball joint nut
40 Nm.
STEERING DAMPER
Service repair no - 57.55.21
Remove
1.Site vehicle on a ramp [hoist].
2.Remove fixings at differential case bracket.
3.Remove fixings at track rod bracket.
4.Remove steering damper.
Refit
5.Reverse removal procedure. 1 to 4.

57STEERING
18
REPAIR TRACK ROD AND LINKAGE
Service repair no - 57.55.09
Remove track rod
1.Site vehicle on a ramp [hoist].
2.Disconnect steering damper at track rod.
3.Disconnect track rod at ball joints, using
extractor LRT-57-018.
4.Remove track rod.
Remove linkage
5.Loosen clamp bolts.
6.Unscrew ball joints.
7.Unscrew track rod adjuster. (left hand thread).
Refit linkage
8.Fit replacement parts. Loosely fit clamp pinch
bolts.
9.Screw in ball joint to full extent of threads.
10.Set adjuster to track rod distance to 9mm as
shown.
11.Set adjuster end ball joint distance to 28.5mm as
shown.
12.Track rod effective length of 1230.0mm is
subject to adjustment during wheel alignment
check.
Refit track rod
CAUTION: Fit a new track rod if existing is
damaged or bent. No attempt should be
made to repair it.
13.Fit track rod and tighten ball joint nuts to
40 Nm.
14.Check front wheel alignment.See Adjustment,
Front Wheel Alignment
15.Connect steering damper to track rod.
16.Remove vehicle from hoist, or axle stands.