steering wheel LAND ROVER DISCOVERY 2002 Service Manual

STEERING
57-48 REPAIRS
Ball joint - track rod
$% 57.55.07
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove LH front road wheel.
3.Loosen adjuster clamp bolts.
4.Remove nut securing track rod ball joint to
steering knuckle.
5.Using tool LRT-57-036 break taper joint and
release track rod.
CAUTION: Before disconnecting any part of
the steering linkage, ensure the road wheels
are positioned straight ahead and the
steering wheel is prevented from turning.
Unrestricted turning of the steering wheel
will damage the SRS rotary coupler.
6.Unscrew ball joint and adjuster.
7.Remove clamps from adjuster and track rod. Refit
1.Clean adjuster, clamps and track rod.
2.Fit clamps to track rod and adjuster. Screw in
adjuster and ball joint.
3.Clean ball joint taper and taper seat.
4.Adjust length of track rod so that ball joint taper
is centralised in steering knuckle.
5.Fit track rod to steering knuckle and tighten nut
to 80 Nm (59 lbf.in).
6.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
7.Remove stand(s) and lower vehicle.
8.Check and, if necessary, adjust wheel
alignment.

+ STEERING, ADJUSTMENTS, Wheel
alignment - front.
9.After check/adjustment of wheel alignment,
ensure track rod adjuster clamp bolts are
tightened. Tighten M8 bolts to 22 Nm (16 lbf.ft)
and M10 bolts to 33 Nm (24 lbf.ft).

STEERING
REPAIRS 57-49
Ball joint - drag link
$% 57.55.15
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2. RHD models: Remove LH front road wheel.
3. LHD models: Remove RH front road wheel.
4.Remove nut securing drag link to steering
knuckle.
5.Using LRT-57-036, break taper joint and
release drag link.
CAUTION: Before disconnecting any part of
the steering linkage, ensure the road wheels
are positioned straight ahead and the
steering wheel is prevented from turning.
Unrestricted turning of the steering wheel
will damage the SRS rotary coupler.
6.Loosen adjuster clamp bolts and unscrew ball
joint and adjuster. 7.Remove clamps from adjuster and drag link.
Refit
1.Clean adjuster, clamps and drag link.
2.Fit clamps to drag link and adjuster. Screw in
adjuster and ball joint.
3.Clean ball joint taper and taper seat.
4.Adjust length of drag link so that ball joint taper
is centralised in steering knuckle.
5.Fit drag link to steering knuckle and tighten nut
to 80 Nm (59 lbf.ft).
6.Tighten drag link adjuster clamp bolts. Tighten
M8 bolts to 22 Nm (16 lbf.ft) and M10 bolts to
33 Nm (24 lbf.ft).
7.Check steering linkage is centralised.

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.
8.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
9.Remove stand(s) and lower vehicle.

STEERING
57-50 REPAIRS
Drag link
$% 57.55.17
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2. RHD vehicles: Remove the LH front road
wheel.
3. LHD vehicles: Remove the RH front road
wheel.
4.Remove nut and bolt securing damper to drag
link and release damper.
5.Remove 2 nuts securing drag link to drop arm
and steering knuckle.
6.Using LRT-57-036 break taper joints and
remove drag link.
CAUTION: Before disconnecting any part of
the steering linkage, ensure the road wheels
are positioned straight ahead and the
steering wheel is prevented from turning.
Unrestricted turning of the steering wheel
will damage the SRS rotary coupler.7.Loosen adjuster clamp bolts and remove ball
joint and adjuster.
8.Remove clamps from adjuster and drag link.
Refit
1.Clean adjuster, clamps and ball joint.
2.Fit clamps to drag link and adjuster. Screw in
adjuster and ball joint.
3.Clean ball joint tapers and taper seats.
4.Fit drag link to drop arm and tighten nut to 80
Nm (59 lbf.ft).
5.Adjust length of drag link so that ball joint taper
is centralised in steering knuckle.
6.Fit drag link to steering knuckle and tighten nut
to 80 Nm (59 lbf.ft).
7.Tighten drag link adjuster clamp bolts. Tighten
M8 bolts to 22 Nm (16 lbf.ft) and M10 bolts to
33 Nm (24 lbf.ft)
8.Align damper to drag link, fit nut and bolt and
tighten to 125 Nm (92 lbf.ft).
9.Check steering linkage is centralised.

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.
10.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
11.Remove stand(s) and lower vehicle.

STEERING
REPAIRS 57-51
Damper - steering
$% 57.55.21
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove 2 nuts and bolts securing steering
damper to drag link and chassis.
3.Compress damper and remove from vehicle.
Refit
1.Position damper to chassis and drag link. Fit
nuts and bolts and tighten to 125 Nm (92 lbf.ft).
2.Remove stand(s) and lower vehicle.
Steering wheel
$% 57.60.01.30
Remove
1.Remove drivers airbag.

+ RESTRAINT SYSTEMS, REPAIRS,
Airbag module - drivers.
2.Disconnect horn multiplug.
3.Centralise steering wheel with road wheels in
straight ahead position.
4.Restrain steering wheel and loosen self locking
nut securing steering wheel to column.
5.Release steering wheel from column.
6.Remove and discard self locking nut.
7.Remove steering wheel.
8.Attach tape across edge of rotary coupler to
retain correct setting.

STEERING
57-52 REPAIRS
9.Release 2 clips securing each horn button to
steering wheel.
10.Remove screw securing horn earth lead to
steering wheel.
11.Disconnect radio and cruise control multiplugs.
12.Remove 2 screws securing radio switches to
steering wheel.
13.Remove radio switches from steering wheel.
14.Remove 2 screws securing cruise control
switches to steering wheel.
15.Remove cruise control switches from steering
wheel.
16.Remove horns from steering wheel. Refit
1.Fit horn switches to steering wheel and secure
with clips.
2.Fit and tighten screw securing horn earth lead
to steering wheel.
3.Fit cruise control switches to steering wheel
and secure with screws.
4.Fit radio switches to steering wheel and secure
with screws.
5.Connect radio and cruise control multiplugs.
6.Remove tape from rotary coupler.
7.Ensure road wheels are in straight ahead
position and indicator cancelling cam are
aligned horizontally.
8.Fit steering wheel to column.
9.Connect horn multiplug.
10.Fit and tighten new self locking nut securing
steering wheel to column to 43 Nm (32 lbf.ft).
11.Fit drivers airbag.
+ RESTRAINT SYSTEMS, REPAIRS,
Airbag module - drivers.

FRONT SUSPENSION
60-32 REPAIRS
Refit
1.Clean lower ball joint location and surrounding
area of axle yoke.
2.Apply a 12 mm (0.5 in) wide yellow paint stripe
on axle yoke, adjacent to lower ball joint
location.
3.Fit tool LRT-54-022 to tool LRT-54-008 and
secure with screw.
4.Fit tool LRT-54-022 and tool LRT-54-008 to
lower ball joint location on axle yoke.
5.Fit new lower ball joint to tool LRT-54-008/14.
6.Fit LRT-54-008/14 and lower ball joint to LRT-
54-008, with lower ball joint positioned on axle
yoke.
7.Align tool assembly and press lower ball joint
into axle yoke.
CAUTION: Damage to the joint boot will
result if the tool is not correctly aligned
during the fitting procedure.
8.Remove tools from axle yoke
9.Fit steering knuckle.

+ FRONT SUSPENSION, REPAIRS,
Steering knuckle.
Steering knuckle
$% 60.15.19
Remove
1.Remove wheel hub.

+ FRONT SUSPENSION, REPAIRS,
Wheel hub.
2.Remove 3 bolts securing mudshield and
remove mudshield.
3.Remove 2 nuts securing track rod and (if
applicable) drag link to steering knuckle.
4.Break taper joints using LRT-57-036, then
position track rod and drag link aside.

FRONT SUSPENSION
REPAIRS 60-33
5.Remove 2 nuts securing ball joints to steering
knuckle.
6.Break taper joints using LRT-54-027 and
remove steering knuckle.
7.Remove tension collet from steering knuckle.
8.Remove drive shaft oil seal from axle casing.Refit
1.Clean taper bores in steering knuckle and
tension collet.
2.Fit tension collet into steering knuckle and
tighten to 5 Nm (3.7 lbf.ft).
3.Clean ball joint tapers and taper seats.
4.Position steering knuckle to axle yoke. Fit
upper ball joint nut and tighten to 110 Nm (81
lbf.ft). Fit lower ball joint nut and tighten to 135
Nm (100 lbf.ft).
5.Clean track rod and (if applicable) drag link
tapers and taper seats.
6.Connect track rod and drag link to steering
knuckle. Fit track rod and drag link nuts and
tighten to 80 Nm (59 lbf.ft).
7.Clean mudshield and steering knuckle mating
faces. Position mudshield, fit bolts and tighten
to 10 Nm (7 lbf.ft).
8.Fit wheel hub.
+ FRONT SUSPENSION, REPAIRS,
Wheel hub.

FRONT SUSPENSION
60-36 REPAIRS
9.Remove 4 bolts securing wheel hub to steering
knuckle.
10.Release wheel hub from steering knuckle, then
remove wheel hub and drive shaft assembly
from axle.
CAUTION: Do NOT remove the ABS sensor
from the hub. The hub and the sensor are
supplied as an assembly.
11.Position the wheel hub and drive shaft on a
press, place supports beneath the wheel studs
and press the drive shaft from the wheel hub.
12.Remove drive shaft oil seal from axle casing. Refit
1.Clean drive shaft oil seal recess, drive shaft
splines, oil seal running surface, wheel hub
and steering knuckle mating faces, ABS
sensor and sensor recess.
2.Lubricate lip of new drive shaft oil seal and
running surface on drive shaft with clean
differential oil.

+ CAPACITIES, FLUIDS AND
LUBRICANTS, Lubrication.
3.Use tool LRT-51-012 to fit new drive shaft oil
seal to axle casing.
4.Fit drive shaft to axle casing.
5.Apply anti-seize compound to wheel hub and
steering knuckle mating face.
M51 0057

FRONT SUSPENSION
REPAIRS 60-37
6.Apply a 3 mm (0.125 in) wide bead of Loctite
640 around drive shaft circumference, as
illustrated.
7.Ensure ABS harness is located in cut out in
steering knuckle.
8.Fit wheel hub to drive shaft and align steering
knuckle. The Loctite will smear along the length
of the splines as the wheel hub is fitted to the
drive shaft.
9.Fit wheel hub bolts and tighten to 100 Nm (74
lbf.ft).
10.Fit new drive shaft nut and lightly tighten.
11.Fit front brake disc.

+ BRAKES, REPAIRS, Brake disc -
front.
12.With assistance, final tighten drive shaft nut to
490 Nm (360 lbf.ft). Stake drive shaft nut. The
drive shaft nut must be tightened before
Loctite has cured.
13.Secure ABS sensor harness to brackets and
secure grommet to inner wing.
14.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
15.Remove stand(s) and lower vehicle.
16.Connect ABS sensor multiplug.
Damper - front
$% 60.30.02
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel.
3. RH damper: Release coolant reservoir and
position aside.
4.Loosen through bolt securing damper to turret.
WARNING: Make sure the axle cannot move
when the damper is disconnected. The
damper limits the downward movement of
the axle. If the axle is not restrained,
disconnecting the damper will allow
unrestricted movement which may cause
personal injury or damage to equipment.
M51 0058

FRONT SUSPENSION
REPAIRS 60-39
Bushes - radius arm
$% 60.35.18
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel.
3.Remove nut securing track rod to steering
knuckle. Use LRT-57-036 to break taper, then
release track rod and position aside.
4.Remove nut and bolt securing radius arm to
chassis. 5.Remove nuts securing radius arm to axle.
Remove rear bolt and lower the radius arm.
Remove front bolt and remove radius arm from
vehicle.
6.Press out bushes from axle end of radius arm
using a length of steel tubing.
7.Press out bush from rear of radius arm:
lUse LRT-60-011/1 and LRT-60-011/2 to
remove bush.