ABS LAND ROVER DISCOVERY 1995 Repair Manual

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

57STEERING
4
FAULT DIAGNOSIS Symptom:-
Fluid leaks from steering box seals.
CAUTION: The steering wheel must not be
held on full lock for more than 30 seconds
in one minute, as this may overheat the
fluid and cause damage to the oil seals.
1.Check fluid level.
See Repair, Power Steering
Fluid Reservoir
Check fluid pressure.See Power Steering
System - Test
2.Is pressure high?
YES - Renew pump.
See Repair, Power
steering Pump
If oil seal leaks persist after renewing the
pump.
See Overhaul, Power Steering
Box
NO -See Overhaul, Power Steering Box
Symptom:-
Insufficient power assistance - castor return
action normal.
1.Are tyres correct type and pressure?
NO -
See GENERAL SPECIFICATION DATA,
Information, Wheels and Tyres
YES - Continue.
2.Is fluid level correct?
NO - Check fluid level
See Repair, Power
Steering Fluid Reservoir
YES - Check system for air locks.See Repair,
Power Steering System - Bleed
3.Is pressure correct?
NO - Check fluid pressure.
See Power
Steering System - Test
If pressure is not correct after bleeding
the system, renew pump.
See Repair,
Power Steering Pump
YES -See Overhaul, Power Steering Box
Symptom:-
Steering heavy - stiff, poor castor return action.
1.Are tyres correct type and pressure?
NO -
See GENERAL SPECIFICATION DATA,
Information, Wheels and Tyres
YES - Check universal joints for seizure and
correct alignment.
See Repair, Lower
Steering Shaft and Universal Joints
Check power steering box adjustments.
See Overhaul, Power Steering Box
2.Is the power assistance satisfactory?
NO - See fault symptomInsufficient
assistance, (castor return action
normal).
YES - Disconnect drag link from drop arm and
check steering column and box for
stiffness.
See Repair, Drag Link and
Drag Link Ends
3.Is the steering stiff with the drag link
disconnected?
NO - Check steering ball joints for seizure and
axle swivels lubrication and resistance.
See Repair, Drag Link and Drag Link
Ends 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
YES - Disconnect the lower steering shaft and
check the column and box for stiffness.
See Repair, Lower Steering Shaft and
Universal Joints
4.Is the steering column stiff to turn when
disconnected from the box?
NO - Remove and overhaul box.
See
Overhaul, Power Steering Box
YES - Adjust steering column.See Stiff
Steering Checklist

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

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.

STEERING
11
FAULT DIAGNOSIS STIFF STEERING CHECKLIST
NOTE: Having completed visual checks
and steering assessment and confirmed
that vehicle steering load is incorrect carry
out the following procedure in order shown.
Steering wheel 'torque to turn' loads
1.Raise vehicle so both front wheels free.
2.With engine off, centralise steering wheel, and
remove air bag, if fitted or steering wheel pad.
Using torque wrench on column nut, check
torque required to turn the steering wheel one
turn in each direction.
3.Record readings obtained in each direction.
Compare figures obtained with the specified
figures:
Without ABS
4.40 Nm.
With ABS4.65 Nm.
NOTE: If figures are in excess of those
specified carry out steering box tie bar
reset below. If figures are as specified.
See Visual Check and Basic Adjustments
Steering box tie bar reset
1.Loosen the three tie bar fixings one complete
turn.
2.Drive vehicle carefully a short distance (within
the dealership) applying full lock in both
directions in order to settle steering components.
Drive vehicle over speed bumps and include
harsh braking if possible.
WARNING: Do not drive on public
highway.
3.Near end of 2. ensure vehicle is driven in a
straight line on level ground and halted.
4.Tighten panhard rod mounting arm nut,
110 Nm.
5.Tighten the two fixings tie bar to steering box,81
Nm.
6.Recheck steering wheel torque to turn. If torque
reading is still greater than specified, carry out
steering shaft universal joint lubrication.Lower steering shaft universal joint lubrication
1.Check lower steering shaft is correctly phased.
See Repair, Lower Steering Shaft and
Universal Joints
2.Lubricate universal joints with an anti-seizure
type penetrating spray. Work the joints to ensure
full penetration of the spray by driving vehicle
and steering from lock to lock.
3.If steering stiffness still persists carry out swivel
pin preload setting.
Swivel pin preload setting
The swivel pin preload setting must be checked and
set following the workshop manual procedure.
1.NON ABS vehicles.
See FRONT AXLE AND
FINAL DRIVE, Overhaul, Front Stub Axle,
Constant Velocity Joint and Swivel Pin
Housing Non ABS
Note that a pull load of 1.16 - 1.46 kg is required
after the axle shaft and swivel housing seal have
been removed.
2.ABS vehicles.
See FRONT AXLE AND FINAL
DRIVE, Overhaul, Front Stub Axle, Constant
Velocity Joint and Swivel Pin Housing ABS
Note that a torque to turn of 2.0 - 2.8 Nm is
required after the axle shaft and swivel housing
seal have been removed.
3.If steering stiffness still persists carry out
steering column alignment.

57STEERING
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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.

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.

STEERING
1
OVERHAUL POWER STEERING BOX
Service repair no - 57.10.07
Overhaul
NOTE: Overhaul of steering box should
not be carried out during the warranty
period.
WARNING: Wear safety glasses while
removing and refitting circlips and
retaining ring.
CAUTION: Absolute cleanliness is
essential when overhauling power steering
box.
1.Remove steering box from vehicle.See Repair,
Power Steering Box
Remove drop arm using extractor LRT-57-012.
Loosen drop arm securing nut, but do not
remove before using extractor. Remove dirt
excluder from output shaft.
2.Drain oil, remove blanking plugs and bleed
screw. Hold steering box over suitable container,
turn input shaft from lock to lock, until oil is
drained. Refit bleed screw.
3.Rotate retainer ring until one end is 12 mm from
extractor hole. Using a drift through hole in
cylinder, lift retaining ring from groove in cylinder
bore.
4.Remove retainer ring, using a screwdriver.
5.Turn input shaft (left lock on left hand drive, right
lock on right hand drive) until piston pushes out
cover. Turn input shaft fully in opposite direction,
applying pressure to piston.
6.Remove set screw retaining rack pad adjuster.
7.Remove rack adjuster and pad.
8.Remove sector shaft adjuster locknut.
9.Remove four bolts from sector shaft cover.
10.Screw in sector shaft adjuster until cover is
removed.
NOTE: Sealant is applied to hexagon
socket to 'tamperproof' sector shaft
adjuster
11.Slide out sector shaft.

STEERING
5
OVERHAUL Rack thrust pad and adjuster
43.Examine thrust pad for scores.
44.Examine adjuster for wear in pad seat.
45.Fit new sealing ring to rack adjuster.
Rack and piston
46.Examine for excessive wear on rack teeth.
47.Ensure thrust pad bearing surface is free from
scores and wear.
48.Ensure piston outer diameters are free from
burrs and damage.
49.Examine seal and ring groove for scores and
damage.
50.Fit new ring to piston. Warm nylon seal and fit to
piston.
51.Slide piston assembly into cylinder with rack
tube outwards.Reassemble
NOTE: When fitting replacement oil seals
lubricate with recommended fluid and
ensure absolute cleanliness.
Sector shaft oil seal
52.Fit oil seal, lip side first.
53.Fit extrusion washer.
54.Fit dust seal, lipped side last.
55.Fit circlip.
Fitting valve and worm assembly
56.Refit original shims and inner bearing cup. Use
Petroleum Jelly to aid assembly.
NOTE: If original shims are not used, fit
shims of 0.76 mm thickness.
57.Fit inner cage and bearings assembly.
58.Fit valve and worm assembly.
59.Fit outer cage and bearings assembly.
60.Fit outer bearing cup.