1995 LAND ROVER DISCOVERY lock

60FRONT SUSPENSION
6
REPAIR ANTI-ROLL[SWAY] BAR BALL JOINT LINKS
Service repair no - 60.10.04.
Remove
1.Remove two nuts, bolts, washers and rubber
bushes from ball joint links.
2.Remove cotter pin and loosen castellated nut a
few turns.
3.Release ball joint using special tool 18G 1063A
as shown.
4.Remove castellated nut and ball joint link.
Refit
5.Fit ball joint link and castellated nut. Ensure ball
joint link arm points up. Tighten to
40Nmand fit
new cotter pin.
6.Align anti-roll bar to ball joint links.
7.Fit bolts, washers and rubber bushes using new
self locking nuts secure anti-roll[sway] bar to ball
joint links. Tighten to
68Nm.

FRONT SUSPENSION
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Anti-roll[sway] bar front
- Strap nyloc nuts 30..............................................................................
- Ball link self lock nut 68........................................................................
- Castellated nut 40................................................................................
Drag link to axle 40.........................................................................................
Securing ring for mounting turret 14...............................................................
Radius arm to chassis 176...............................................................................
Panhard rod mounting arm to chassis 88.......................................................
Panhard rod to axle 88....................................................................................
Panhard rod to mounting bracket 88...............................................................
Tie bar to Panhard rod 110..............................................................................
Radius arm to axle (front only) 197..................................................................
Torque values below are for all screws and bolts used except for those that are specified otherwise.
METRIC Nm
M5 6...........................................................................
M6 9...........................................................................
M8 25...........................................................................
M10 45.........................................................................
M12 90.........................................................................
M14 105.........................................................................
M16 180.........................................................................
UNC / UNF
1/4 9...........................................................................
5/16 24.........................................................................
3/8 39...........................................................................
7/16 78.........................................................................
1/2 90...........................................................................
5/8 136...........................................................................

REAR SUSPENSION
3
REPAIR Renew bush
7.Press out rubber bushes.
8.Fit bush centrally in housing.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
Refit
9.Reverse removal procedure. 1 to 6. Do not fully
tighten fixings until all components are in
position.
10.Tighten fixings to correct torque.
See
Specifications, torque, Torque Values
SUSPENSION LINK LOWER
Service repair no - 64.35.02.
Remove
1.Site vehicle on a ramp [hoist].
2.Alternatively, support vehicle on stands under
rear axle.
3.Remove rear fixings.
4.Remove mounting bracket fixings at side
member bracket.
5.Remove lower link complete.
6.Remove locknut.
7.Remove mounting bracket from lower link.
Renew bush
8.Press out rubber bushes.
9.Fit bush centrally in housing.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
Refit
10.Reverse removal procedure. 6 and 7. Do not
tighten locknut.
11.Reverse removal procedure. 3 to 5.
12.Lower vehicle, allow axle to take up static laden
position. Tighten to
176 Nm.

REAR SUSPENSION
5
REPAIR ANTI-ROLL[SWAY] BAR BALL JOINT LINKS
Service repair no - 64.35.24.
Remove
1.Remove two nuts, bolts, washers and rubber
bushes from ball joint links and lower anti-roll bar
to clear links.
2.Remove cotter pin and loosen castellated nut a
few turns.
3.Release ball joint using special tool 18G 1063A
as shown.
4.Remove castellated nut and ball joint link.
Refit
5.Fit ball joint link arm and castellated nut. Point
ball joint link arm down as shown. Tighten to
40Nmand fit new cotter pin.
6.Align anti-roll bar to ball joint links.
7.Fit bolts, washers and rubber bushes using new
self locking nuts secure anti-roll bar to ball joint
links. Tighten to
68Nm.

REAR SUSPENSION
1
SPECIFICATIONS, TORQUE TORQUE VALUES
NOTE: Torque wrenches should be regularly checked for accuracy to ensure that all fixings are
tightened to the correct torque.
Nm
Anti-roll[sway] bar rear
- Strap nyloc nuts 30..............................................................................
- Ball link self lock nut 68........................................................................
- Castellated nut 40................................................................................
Top link to mounting bracket 176.....................................................................
Bottom link to axle 176.....................................................................................
Bottom link to chassis 176...............................................................................
Top link bracket to rear cross member 47......................................................
Shock absorber to axle 37..............................................................................
Torque values below are for all screws and bolts used except for those that are specified otherwise.
METRIC Nm
M5 6......................................................................................................
M6 9......................................................................................................
M8 25.....................................................................................................
M10 45...................................................................................................
M12 90...................................................................................................
M14 105..................................................................................................
M16 180..................................................................................................
UNC / UNF
1/4 9......................................................................................................
5/16 24...................................................................................................
3/8 39.....................................................................................................
7/16 78...................................................................................................
1/2 90.....................................................................................................
5/8 136....................................................................................................

BRAKES
1
DESCRIPTION AND OPERATION BRAKES
Discovery vehicles have servo assisted brake
systems and the option of an anti-lock brake system.
Information in this section refers to components
relevant to both brake systems. Where the system
components are different they are referred to as ABS
or NON ABS
BRAKE SYSTEM NON ABS
Description
The servo assisted hydraulic braking system is the
dual line type, incorporating primary and secondary
hydraulic circuits.
NOTE: References made to primary or
secondary do not imply main service
brakes or emergency brakes but denote
hydraulic line identification.
The brake pedal is connected to a vacuum assisted
mechanical servo which in turn operates a tandem
master cylinder. The front disc brake calipers each
house four pistons, these pistons are fed by the
secondary hydraulic circuit. The rear disc brake
calipers each house two pistons, these are fed by the
primary hydraulic circuit via a pressure reducing valve.
A brake fluid level switch is incorporated into the
reservoir cap assembly, the switch will immediately
illuminate a warning light in the instrument binnacle
indicating low fluid or sudden fluid loss.
The brake fluid reservoir is divided, the section closest
to the servo feeds the primary circuit and the section
furthest from the servo feeds the secondary circuit.
Under normal operating conditions both the primary
and secondary circuits operate simultaneously on
brake pedal application. In the event of a failure in the
primary circuit the secondary circuit will still function. If
the secondary circuit fails the primary circuit will still
function. The brake pedal travel will be longer in the
event of a half system failure.If the servo should fail, both hydraulic circuits will still
function but would require greater pedal effort due to
the lack of vacuum assistance. The hand operated
parking brake acts on a brake drum at the rear of the
transfer gearbox and is completely independent of the
hydraulic circuits.
Hydraulic circuit non ABS
Key
A = Primary hydraulic circuit
B = Secondary hydraulic circuit
C = Pressure reducing valve

BRAKES
3
DESCRIPTION AND OPERATION Description of components
1. ABS Modulator unit
To provide the ABS function a Modulator is positioned
within the system between the master cylinder and the
calipers. On both LHD and RHD vehicles it is sited on
the left inner wing [fender]. The Modulator has 8
solenoid valves, 2 for each wheel, 2 expanders and a
recirculation pump. It is non serviceable.
2. Servo/master cylinder
Actuation of the system is provided by a combined
master cylinder and servo assembly attached to the
pedal box, this provides pressure to opposed piston
calipers at each brake pad Twin piston at the front
axle, single piston at the rear.
3. Pressure reducing valve
To maintain the braking balance, pressure to the rear
axle is regulated by a Pressure Reducing Valve (PRV)
This PRV is of the failure bypass type, allowing full
system pressure to the rear axle in the event of a front
circuit failure. It is sited on the left inner wing [fender].
4. Electronic control unit - ECU
ABS control is provided by an electronic control unit
which is positioned on the passenger side of the
vehicle behind the dash panel/glove box.
The ECU, which is non-serviceable, is connected to
the ABS harness by a 35 way connector. non
serviceable.
The ECU continually monitors the brake system,
providing diagnostics in the event of a system
malfunction. Details of how to access the ECU
diagnostics are provided in the Electrical
Troubleshooting Manual.
5.& 6. Front and rear sensors/exciter rings - 4 off
A sensor is sited at each wheel, sensing a 60 tooth
exciter ring. When vehicle is in motion inductive
sensors send signals to ECU. Front exciter ring is
fitted to outside diameter of constant velocity joint
inside each front hub assembly. The rear exciter ring
is bolted to the rear of each brake disc bell.7. Diagnostic plug connection
A diagnostic plug is located behind the dash. To the
left of the steering column on LHD vehicles. To the
right of the steering column on RHD vehicles. It is a 5
way blue connector.
The location and identification of ABS electrical relays
are given in the Electrical Troubleshooting Manual.
For location and identification of ABS electrical fuses.
See ELECTRICAL, Repair, Fuse Box - Interioror.
See ELECTRICAL, Repair, Fuse Box - Engine
Compartment
ANTI-LOCK BRAKE SYSTEM - ABS
Manufactured by WABCO
Introduction
The purpose of ABS is to prevent vehicle wheels
locking during brake application, thus maintaining
vehicle steerability and stability. This allows vehicle to
be steered whilst brakes are applied, even under
emergency conditions, and to avoid obstacles where
there is sufficient space to redirect the vehicle.
WARNING: ABS is an aid to retaining
steering control and stability while
braking.
·ABS cannot defy the natural laws of physics
acting on the vehicle.
·ABS will not prevent accidents resulting from
excessive cornering speeds, following
another vehicle too closely or aquaplaning,
i.e. where a layer of water prevents adequate
contact between tyre and road surface.
·The additional control provided by ABS must
never be exploited in a dangerous or
reckless manner which could jeopardise the
safety of driver or other road users.
·The fitting of ABS does not imply that the
vehicle will always stop in a shorter stopping
distance.

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.