1995 LAND ROVER DISCOVERY service

ZF
5
SERVICE TOOLS
LRT-44-009 Adaptor pressure take off.
LST 502-1
LRT-44-010 Convertor lifting handles.
18G.1501

PROPELLER SHAFTS
1
REPAIR FRONT PROPELLER SHAFT
Service repair no - 47.15.02 - Front
Remove
1.Place vehicle over pit or on a ramp [hoist].
2.Remove nuts from each end of propeller shaft.
Remove shaft.
3.Scribe alignment marks on flanges at both ends
of propeller shaft to ensure correct refitting.
Service repair no - 47.15.11
Overhaul
4.Thoroughly examine universal joint for signs of
damage or wear. Replace if necessary.
5.Clean universal joint bearing cups and circlips.
CAUTION: To ensure correct assembly
and reduce possibility of imbalance.
Before removing propeller shaft joint. Mark
position of spider pin lubricator relative to journal
yoke ears.
6.Remove circlips, and grease nipple.
7.Tap yokes to eject bearing cups.
8.Remove bearing cups and spider.
9.Repeat instructions 4 to 7 for opposite end of
propeller shaft if necessary.
10.Clean yokes and bearing cup locations.
Assemble
11.Remove bearing cups from new spider.
12.Check all needle rollers are present and
positioned in bearing cups.
13.Ensure bearing cups are one-third full of
lubricant.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
14.Enter new spider with seals into yokes of sliding
member flange.
15.Partially insert one bearing cup into flange yoke
and enter spider trunnion into bearing cup.
16.Insert opposite bearing cup into flange yoke.
17.Press both cups into place.

47PROPELLER SHAFTS
4
REPAIR REAR PROPELLER SHAFT
Service repair no - 47.15.03
NOTE: SGF rubber coupling should be left
attached to propeller shaft. Only remove
coupling from propeller shaft if
replacement is required.
Remove
1.Scribe alignment marks on flanges at both ends
of propeller shaft to ensure correct refitting.
2.Remove three nuts and bolts securing flexible
coupling to axle flange.
3.Remove nuts securing propeller shaft flange to
transfer gearbox.
4.Raise propeller shaft at gearbox end detach
coupling from spigot at differential and withdraw
shaft.
NOTE: For replacement of spigot (pinion
flange centralising peg).
See REAR AXLE
AND FINAL DRIVE, Overhaul, Axle
Differential Assembly
Overhaul
Service repair no - 47.15.12
NOTE: Refer to front propeller shaft
overhaul procedure for gearbox end of
shaft. The SGF rubber coupling is a
non-serviceable item.
Refit
5.Locate flexible coupling over spigot, align
scribed marks and secure at transfer gearbox.
Tighten to
47 Nm.
6.Secure flexible coupling to axle flange with three
nuts and bolts and Tighten to
78 Nm.
FLEXIBLE COUPLING
NOTE: Flexible coupling should only be
removed if a new coupling is to be fitted.
Remove
1.Remove rear propeller shaft.
See Rear
Propeller Shaft.
2.Remove nuts and bolts securing flexible
coupling to propeller shaft.
Refit
3.Reverse removal procedure. Fit nuts and bolts.
Tighten to
78 Nm.

REAR AXLE AND FINAL DRIVE
1
REPAIR REAR AXLE
Service repair no - 51.25.01
Remove
WARNING: Remove and refit of axle
requires a further two persons to steady
the axle when lowering or repositioning
axle.
1.Drain brake system.
2.Support chassis rear.
3.Remove road wheels.
4.Support axle weight with hydraulic jack.
5.Disconnect ABS wiring harness multi-plug at
jump hose bracket, if applicable.
6.Disconnect shock absorbers.
7.Disconnect flexible brake hose at connection
under floor.
8.Disconnect lower links at axle.
9.Mark differential and propeller shaft flanges with
identification marks for assembly. Remove four
nuts and bolts. Lower propeller shaft and tie to
one side.10.Disconnect pivot bracket ball joint at axle
bracket.
11.Release bolts and remove coil spring retaining
plates.
12.Lower axle and remove road springs.
13.Disconnect anti-roll[sway] bar links to axle.
See
REAR SUSPENSION, Repair, Anti-Roll[Sway]
Bar Ball Joint Links
14.Remove axle assembly.
Refit
15.Position axle and fit lower links. Tighten to
176
Nm
16.Reverse removal procedure.
17.Tighten pivot bracket ball joint to axle to
176 Nm.
18.Tighten propeller shaft to differential drive flange
to
47 Nm
19.Bleed brake system.See BRAKES, Repair,
Brake System Bleed

51REAR AXLE AND FINAL DRIVE
2
REPAIR REAR BRAKE DISC NON ABS
Service repair no - 70.10.11.
Remove
1.Remove rear hub assembly.
See Rear Hub
Assembly
2.Remove disc bolts.
3.Remove disc from rear hub.
Refit
4.Fit disc to rear hub.
5.Fit disc bolts. Tighten to
73 Nm.
6.Check total disc run out, this must not exceed
0,15 mm. If necessary reposition disc.
7.Fit rear hub assembly.See Rear Hub
Assembly
Disc reclamation
8.Check disc thickness. This dimension may be
reduced to minimum thickness of 12 mm.
Machine equal amounts off each face.REAR BRAKE DISCS ABS
Service repair no - 70.11.11.
Remove
1.Remove rear hub assembly.
See Rear Hub
Assembly
2.Remove five nyloc nuts.
3.Remove sensor ring.
4.Remove five hub to disc retaining bolts.
5.Remove disc from hub.
Refit
6.Fit disc onto hub.
7.Apply loctite 270 and fit hub to disc retaining
bolts. Tighten to
73 Nm.
8.Using new nyloc nuts fit sensor ring.
9.Check total disc run out, this must not exceed
0,15 mm. If necessary reposition disc.
10.Fit hub assembly.
See Rear Hub Assembly
Disc reclamation
11.Check disc thickness. This dimension may be
reduced to a minimum thickness of 12 mm.
Machine equal amounts off each face.

REAR AXLE AND FINAL DRIVE
3
REPAIR REAR HUB ASSEMBLY
Service repair no - 64.15.01
Remove
1.Place rear axle onto axle stands and remove
road wheel.
2.Release brake hose clips and remove brake
caliper bolts. Secure to one side.
WARNING: Take care not to kink brake
hose.
3.Remove five bolts and withdraw axle shaft.
4.Remove joint washer.
5.Bend back lock washer tabs.
6.Remove locknut and lock washer.
7.Remove hub adjusting nut.
8.Remove spacing washer.
9.Remove hub and brake disc assembly complete
with bearings.REAR HUB COMPONENTS
1. Sensor ring retaining nut ABS.
2. Axle shaft.
3. Axle shaft joint washer.
4. Axle shaft retaining bolt (five off).
5. Lock nut.
6. Lock washer.
7. Hub adjusting nut.
8. Spacing washer.
9. Outer bearing.
10. Hub.
11. Inner bearing.
12. Grease seal.
13. Brake disc.
14. Disc retaining bolt (five off).
15. Sensor ring ABS.

REAR AXLE AND FINAL DRIVE
1
OVERHAUL AXLE DIFFERENTIAL ASSEMBLY
Service repair no - 51.15.07.
DISMANTLE
NOTE: Mark differential components so
their original positions relative to other
components is maintained. Bearing caps
must not be interchanged.
1.Remove axle shafts then differential assembly
fom axle.
2.Remove roll pin securing bearing nut locking
fingers to bearing caps. Remove locking fingers.
3.Loosen bearing cap bolts and mark caps for
assembly.
4.Using service tool LRT-54-508, remove bearing
adjusting nuts.
5.Remove bearing cap bolts and bearing caps.
6.Remove crown wheel differential unit and
bearings.
Remove pinion FRONT AXLE DIFFERENTIAL
ONLY
7.Remove pinion flange nut using service tool
LRT-51-003 to restrain flange.
8.Remove washer and pinion drive flange.
9.Remove pinion complete with bearing and outer
bearing shims.
10.Remove pinion flange oil seal, spacer and
bearing.
Remove pinion REAR AXLE DIFFERENTIAL ONLY
7.Remove pinion flange centralizing peg using
service tool LRT-51-008.
8.Remove pinion flange nut using service tool
LRT-51-003 to restrain flange.
9.Remove pinion complete with bearing and outer
bearing shims.
10.Remove pinion flange oil seal and bearing.
11.Using service tool LRT-54-505, remove pinion
head bearing track and shim and drive out outer
bearing of differential housing.

51REAR AXLE AND FINAL DRIVE
2
OVERHAUL
12.Remove pinion head bearing with service tool
LRT-99-002.
13.Remove bolts and washers securing crown
wheel to differential flange. Remove crown
wheel.
14.Remove differential carrier bearings.
15.Remove circlips and extract differential cross
shaft.
16.Withdraw differential gears and pinions.
17.Clean all components.
INSPECTION
18.Check all bearings for wear and pitting.
19.Check all gears for wear, scuffing, pitting and
damaged teeth.
20.Supplied as matched sets are: crown wheel and
pinion, pinion housing and bearing caps.
ASSEMBLE
Differential gears
21.Fit differential gears to differential housing.
22.Fit differential cross shaft and circlips.