1995 LAND ROVER DISCOVERY washer fluid

CLUTCH
1
OVERHAUL MASTER CYLINDER
Service repair no - 30.20.07
1.Remove master cylinder.
See Repair, Master
Cylinder
Disassemble
2.Pull back and remove rubber sealing boot from
pushrod.
3.Depress push-rod and extract circlip.
4.Withdraw push-rod assembly.
5.Withdraw piston assembly.
6.Withdraw retainer and spring.
7.Remove two piston seals and piston washer.
Inspecting
8.Clean all components thoroughly using new
hydraulic fluid. Dry, using a lint-free cloth.
9.Examine cylinder bore and piston, ensure they
are smooth to touch with no corrosion, score
marks or ridges. If in doubt, fit new components.
10.Fit new seals and rubber boot. These items are
all included in master cylinder overhaul kit.
11.Ensure that feed and by-pass ports are not
obstructed.
12.Ensure reservoir cap vent is clear.
Assemble
NOTE: Cleanliness is essential, ensure
hands are free of grease or dirt. Lubricate
cylinder bore and rubber seals with new
hydraulic fluid before assembly.
13.Fit a new piston washer and thinner of two piston
seals, lip last, over piston nose, up against
drilled piston head. Fit thicker seal into piston
groove with lip facing towards seal at opposite
end.
14.Insert spring and retainer into master cylinder
bore.
15.Insert piston and seal assembly, ensuring that
seal lips do not bend back.
16.Reverse 3 and 4, correctly locating circlip.
17.Stretch new rubber boot over push-rod, pack
with rubber grease. Fit securely into locating
groove.
18.Operate push-rod several times to ensure free
movement of internal components.
19.Fit master cylinder.

TRANSFER GEARBOX
3
REPAIR Refit
36.Select 'P' in main gearbox, with low range and
differential lock selected in transfer gearbox.
37.Secure transfer gearbox to adaptor plate on
lifting hoist.
38.Ensure joint faces of transfer and main
gearboxes are clean and guide studs 18G 1425
are fitted.
39.Raise hoist until transfer gearbox can be located
over guide studs to main gearbox. At the same
time locate high/low lower link to yoke.
40.Remove guide studs and secure transfer
gearbox to main gearbox.41.Complete refitting by reversing removal
procedure, noting the following important points.
42.After removal of adaptor plate from transfer
gearbox, clean threads of four bottom cover
bolts, coat threads with Loctite 290 and fit
together with spring washers. Tighten to
25Nm
43.Add correct grade of oil to transfer gearbox to oil
level plug hole.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
44.Check main gearbox oil level.
45.Check operation of parking brake and adjust as
necessary.
See SECTION 10, Maintenance,
Vehicle Interior

ZF
7
REPAIR Accessories removal/fitting
If fitting a replacement transmission assembly to the
vehicle, remove the following items from the existing
assembly and fit to the replacement.
CAUTION: It is important to remove the
spacer from the extension shaft and fit
onto the replacement unit.
50.Breather pipe union and washers from main
gearbox.
51.Breather pipe, union and washers from transfer
gearbox.
52.Main gearbox selector lever.
53.RH mounting bracket assembly.
54.Oil cooler pipe unions.
55.Fit blanks to all apertures where unions have
been removed and blank off pipe ends.
Refit
1.Fit transmission to cradle and hoist.
2.Locate hoist under vehicle and remove torque
convertor retaining strap.
3.Ensure low range gear is engaged.
4.Apply approved sealant to bell housing face.
5.Carefully raise assembly, align bell housing with
flywheel housing and bring mating faces
together.
6.Fit nuts and bolts to secure transmission to
engine.
7.Locate electrical wiring and breather pipes to
position.
8.Secure kick down cable clip to bell housing.
9.Raise hoist sufficiently to take weight.
10.Remove block and jack from engine sump.
11.Fit filler/dipstick tube to gearbox sump and
secure bracket to bell housing.
12.Apply Loctite to torque convertor bolts
13.Working through starter aperture refit the four
torque convertor to flexible drive securing bolts,
rotating crankshaft to gain access to bolt
locations.
14.Refit starter and heatshield.
15.Secure breather pipes and harness with ties.
16.Fit left hand mounting bracket assembly to
gearbox.
17.Raise transmission and support with a suitable
ramp [hoist] jack.
18.Remove two bolts securing transmission to
cradle, lower hoist and remove from under
vehicle.
19.Apply Loctite to above bolts and fit to transfer
gearbox input bearing support plate.
20.Fit chassis cross member.21.Secure gearbox mounting brackets to chassis
cross member.
22.Remove ramp [hoist] jack.
23.Connect electrical leads to differential lock
switch.
24.Connect inhibitor switch multi-plug.
25.Connect selector cable to lever on side of
gearbox.
26.Connect oil cooler pipes to gearbox and secure
retaining bracket to gearbox sump.
27.Secure silencer to chassis and refit exhaust front
pipe.
28.Refit front propeller shaft to transfer gearbox.
29.Refit rear propeller shaft.
See PROPELLER
SHAFTS, Overhaul, Flexible Coupling
30.Connect speedometer cable to transfer gearbox.
31.Refill transfer gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids
32.Lower ramp [hoist] to ground level.
33.Reconnect turbo-charger hose to inter-cooler.
34.Reconnect top hose to radiator.
35.Refill cooling system with correct mixture of
coolant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
36.Reconnect kick down cable to fuel injection
pump.
37.Secure breather pipe clip to rear of cylinder
head.
38.Engage harness with clips along top of
bulkhead.
39.On left hand drive vehicles only, connect
multi-plug to top of brake fluid reservoir.
40.Refit insulation pad to rocker cover and inlet
manifold, secure with oil filler cap.
41.Refit gaiter and knob to transfer gear lever.
42.Select high range gear.
43.Reconnect battery terminals.
44.Refill main gearbox with correct grade of
lubricating oil.
See LUBRICANTS, FLUIDS
AND CAPACITIES, Information,
Recommended Lubricants and Fluids

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.

BRAKES
3
REPAIR MASTER CYLINDER ABS
Service repair no - 70.30.08
- Lucas Girling - Type 25.4mm CV/CV
NOTE: This master cylinder is identified by
a 3rd plugged outlet port protruding down
from the master cylinder body.
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
Remove
1.Disconnect battery negative lead.
2.Place a suitable container under master cylinder
to catch brake fluid from cylinder when brake
pipes are disconnected.
3.Thoroughly clean immediate area around all
outlet ports. Remove each brake pipe, sealing
each pipe and outlet port with suitable plugs to
prevent ingress of foreign matter.
4.Disconnect electrical plug from low fluid switch
on reservoir cap.
5.Remove two nuts securing master cylinder to
servo unit remove also spring and plain washers.
6.Detach master cylinder from servo, remove
reservoir cap and drain brake fluid into a
container.Refit
NOTE: Ensure O ring seal between master
cylinder and servo unit is fitted correctly.
7.Fit master cylinder to servo. Secure in position
with two nuts, plain and spring washers. Tighten
to
26 Nm.
8.Fit brake pipes to master cylinder. Tighten to
15Nm.
9.Top-up master cylinder with correct grade of
brake fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
10.Bleed system.See Brake System Bleed
11.Fit cap, reconnect electrical lead to fluid level
switch. Reconnect battery negative lead.

70BRAKES
4
REPAIR MASTER CYLINDER NON ABS
Service repair no - 70.30.08 - Remove
Service repair no - 70.30.09 - Repair
- Lucas Girling - Type 25.4mm AS/AS
WARNING: This master cylinder is not
suitable to be fitted on vehicles with
antilock brake systems.
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
Remove
1.Disconnect battery negative lead.
2.Place a suitable container under master cylinder
to catch brake fluid from cylinder when brake
pipes are disconnected.
3.Thoroughly clean immediate area around all
outlet ports. Remove each brake pipe, sealing
each pipe and outlet port with suitable plugs to
prevent ingress of foreign matter.
4.Disconnect electrical plug from low fluid switch
on reservoir cap.
5.Remove two nuts securing master cylinder to
servo unit remove also spring and plain washers.
6.Detach master cylinder from servo, remove
reservoir cap and drain brake fluid into a suitable
container.Repair
7.Thoroughly clean master cylinder and inspect
outer surfaces for damage and condition, renew
complete assembly if necessary.
8.Using two soft jaws, clamp master cylinder
flange in a suitable vice. Remove water ingress
'O' ring seal from master cylinder to servo flange
and discard.
9.Grip outside of transfer housing with a suitable
pair of pliers, carefully pull, working pliers in a
backwards and forwards rocking motion to ease
housing off master cylinder. Discard housing and
vacuum seal.

70BRAKES
6
REPAIR
NOTE: The primary plunger assembly
cannot be broken down any further and is
serviced as a complete unit. Discard
assembly.
15.The secondary plunger assembly will remain at
bottom of master cylinder bore. Remove tapping
assembly on a piece of wood until plunger
appears at cylinder mouth, carefully pull plunger
out of master cylinder.
16.If swirl tube was not expelled at same time as
secondary plunger, repeat above operation to
remove it from bottom of master cylinder bore
and discard.
17.Clean all parts with unused brake fluid. Place
cleaned parts onto a clean sheet of paper.
Inspect cylinder bore and plungers for signs of
corrosion, ridges and score marks. Provided
working surfaces are in perfect condition, new
seals from a Girling Service repair kit may be
used.
Renewing secondary plunger seals
18.Remove following components from secondary
plunger and discard:
NOTE: A small screwdriver with end
rounded off and polished is required to
remove 'L' seal. DO NOT damage
secondary plunger.
(A) Springs
(B) Seal retainer
(C) Recuperating seal (primary cup)
(D) Washer
(E) 'L' seal

BRAKES
7
REPAIR 19.Coat new seals in unused brake fluid. Fit 'L' seal
to plunger.
20.Fit washer followed by recuperating seal. Fit seal
retainer and springs, ensure springs are
correctly seated.
Assembling master cylinder
CAUTION: It is important that following
instructions are carried out precisely,
otherwise damage could be caused to new
seals when inserting plungers into cylinder bore.
Generous amounts of new brake fluid should be
used to lubricate parts during assembly.
21.Fit new swirl tube to bottom of cylinder bore.
22.Lubricate secondary plunger and cylinder bore.
Offer plunger assembly to cylinder until
recuperation seal is resting centrally in mouth of
bore. Gently introduce plunger with a circular
rocking motion, as illustrated. Ensuring that seal
does not become trapped, ease seal into bore
and slowly push plunger down bore in one
continuous movement.
23.Fit new primary plunger assembly using same
method as for secondary plunger.
24.Fit original guide ring to support primary plunger.
25.Coat a new 'O' ring with brake fluid and fit to its
respective groove on outer location surface of
master cylinder.
CAUTION: Do not roll 'O' ring down outer
location surface of master cylinder. It
should be slightly stretched and eased
down cylinder and into its groove. Do not over
stretch seal.
26.Fit new retaining ring on outer surface of master
cylinder ensuring that serrations of ring are
facing mounting flange.
27.Fit two new reservoir seals in respective ports.
28.Fit a new vacuum seal to either primary plunger
or to bottom of transfer housing bore, open face
of seal towards primary plunger.
29.Lubricate vacuum seal with brake fluid. Fit
transfer housing to master cylinder, push
housing fully up to cylinder mounting flange, Do
not adjust transfer housing after fitting.
30.Lubricate new water ingress seal with brake
fluid, Slightly stretch seal and ease down
housing until it is in position between housing
and flange.
31.Roll reservoir into top of master cylinder,
reversing procedure described in instruction 10.
Refit
NOTE: Ensure O ring seal between master
cylinder and servo unit is fitted correctly.
32.Fit master cylinder to servo. Secure in position
with two nuts, plain and spring washers. Tighten
to
26 Nm.
33.Fit brake pipes to master cylinder. Tighten to
15Nm.
34.Top-up master cylinder with correct grade of
brake fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
35.Bleed system.See Brake System Bleed
36.Fit cap, reconnect electrical lead to fluid level
switch. Reconnect battery negative lead.