1995 LAND ROVER DISCOVERY ESP

ZF
3
REPAIR 19.Disconnect rear propeller shaft to output flange,
and tie to one side.
20.Repeat instructions 18 and 19 on front propeller
shaft to main gearbox.
21.Remove bolts retaining silencer front and rear
securing brackets and tie silencer to one side.
22.Disconnect oil cooler feed and return pipes from
bottom and side of main gearbox.
23.Release cooler pipes from clamp at engine sump
and remove distance piece.
24.Blank pipe ends and unions.
25.Move oil cooler pipes clear of transmission and
tie aside.
26.Disconnect selector cable from operating lever.
27.Disconnect inhibitor switch at multiplug.
28.Attach adaptor plate to hoist.
29.Remove two bolts from transfer gearbox rear
cover.
30.Raise hoist to align adaptor plate with transfer
gearbox and transmission. Secure to transfer
gearbox at rear cover with two bolts removed.
31.Adjust hoist to take weight of transmission.
32.Remove nuts and bolts securing right transfer
gearbox mounting bracket to chassis.
33.Repeat for the left mounting bracket. Removal of
these fixings will also free speedometer
transducer bracket
34.Remove right side mounting bracket to flexible
mounting rubber retaining nut.
35.Lower hoist until rear brake drum clears
passenger footwell. Check engine does not
crush any components while lowering.
36.Remove clip and clevis pin from park brake
lever.
37.Remove clip securing outer brake cable
38.The park brake cable is now free.
39.Disconnect leads from transfer gearbox
temperature sensor and differential lock warning
light switch.
40.Remove ties securing breather pipes to harness.
41.Remove bell housing access plate complete with
gasket.
42.Rotate engine, using crankshaft pulley, until two
access holes are visible in drive plate/ring gear
assembly through bell housing bottom cover
opening.
43.Identify an access hole and bolt hole to aid
reassembly.
44.Remove bolts securing drive plate to convertor
through access holes.
45.Rotate crankshaft half turn to access and
remove remaining bolts.
46.Disconnect oil dipstick tube at main gearbox.
47.Remove bolt at bell housing and detach dipstick
tube. Blank pipe end and union.
48.Position hoist jack channel under engine and
support using a wooden block.
49.Remove bell housing to engine securing bolts,
also detach harness bracket from bell housing.
50.Ease transmission rearwards to allow access to
secure torque converter in bell housing.
51.Lower hoist and complete removal of
transmission.
Refit
52.Ensure torque converter is retained in bell
housing.
53.Secure transmission to adaptor plate on lifting
hoist.
54.Raise hoist and locate transmission with engine.
55.Remove torque converter retainer.
56.Complete attachment of transmission to engine
and fit bell housing bolts. Fit the dipstick tube
bracket and harness bracket to their respective
bolts.
57.Complete refitting by reversing removal
procedure. Note the following important points.
58.Drive plate to torque converter bolts are to be
coated with Loctite 290 prior to assembly.
59.Refill transfer and main gearboxes with correct
grade oil.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
60.Check operation of parking brake and adjust as
necessary.
See SECTION 10, Maintenance,
Vehicle Interior

47PROPELLER SHAFTS
2
REPAIR 18.Press each cup into its respective yoke up to
lower land of circlip grooves. Damage may be
caused to cups and seals if cups pass this point.
19.Fit circlips and check no end float exists.
20.Engage spider in yokes of sliding member. Fit
bearing cups and circlips as described in
instructions 14 to 19.
21.Fit grease nipples to spider and sliding member.
22.Apply instructions 14 to 19 to opposite end of
propeller shaft.
23.Fit grease nipple and lubricate.
Refit
24.Fit propeller shafts to vehicle and tighten nuts to
47Nm
Refit FRONT propeller shaft so sliding joint end
of shaft is fitted to transfer gearbox.

BRAKES
7
DESCRIPTION AND OPERATION BRAKE SERVO UNIT
Description
The power assistance for the brake system is
provided by a twin diaphragm suspended vacuum
servo.
A 'Suspended Vacuum' servo is one where, with the
engine running vacuum is present both sides of the
diaphragm or diaphragms when the brakes are fully
released or partially applied. The principal of having
vacuum both sides of the diaphragm has two main
advantages. First, it ensures instantaneous servo
response to the brake being applied or released and
second, it provides very accurate control of the
position of the diaphragm and therefore, the degree of
partial brake application.At full pedal depression, vacuum is present in front of
the diaphragm with atmospheric pressure on the rear.
Operation
Brakes released
With the brakes released depression is present both
sides of the diaphragms, in chambers 1,2,3 and 4.
The chambers comunicate by ports A, B, D via the
valve C which is shown fully released in RR3640M.

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.

BRAKES
9
REPAIR SERVO ASSEMBLY
Service repair no - 70.50.01
Remove
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
NOTE: The filter, non-return valve and
grommet, are the only serviceable
components, in event of failure or damage
fit a new unit.
1.Disconnect battery negative lead.
2.Disconnect electrical plug to low fluid level
switch.
3.Thoroughly clean immediate area around all
master cylinder outlet ports. Remove each brake
pipe, sealing each pipe and outlet port to prevent
ingress of foreign matter.
4.Disconnect vacuum supply hose to servo.
5.Remove lower dash panel to gain access to
servo push rod to brake pedal.
6.Remove clevis pin securing servo push rod to
brake pedal.
7.Remove two nuts and plain washers securing
servo.
8.Remove servo and master cylinder assembly.
9.Drain brake fluid into a suitable container. (If
master cylinder is kept horizontal it is not
necessary to drain fluid).10.Detach spacer from pedal box mounting face of
servo.
NOTE: Retain spacer for reassembly. The
spacer ensures stringent pedal to servo
operating dimensions are maintained.
11.Remove master cylinder from existing servo and
refit to new servo, if fitting new unit.
Refit
12.Fit spacer to servo.
13.Fit servo to pedal box.
14.Lightly grease brake pedal around area servo
push rod pivots.
15.Fit push rod to lower hole of brake pedal. Fit
clevis pin and clip.
16.Secure servo with two nuts and plain washers.
Tighten nuts to
26 Nm.
17.Refit lower dash panel.
18.Fit master cylinder to servo, refit nuts, plain and
spring washers. Tighten nuts to
26 Nm.
19.Remove all sealing plugs. Refit brake pipes to
respective ports. Tighten brake pipes to
15 Nm.
20.Refit vacuum supply hose.
21.Fill master cylinder to correct level using correct
grade of brake fluid.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids
22.Bleed brake system.See Brake System Bleed

BRAKES
13
REPAIR FRONT BRAKE CALIPERS
Service repair no - 70.55.03
Service repair no - 70.55.16
Service tool:
LRT-70-500 - Piston clamp
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
Remove caliper
1.Loosen front wheel retaining nuts, raise front of
vehicle, lower onto axle stands, remove wheels.
2.Expose flexible brake hose by moving coiled
protective covering.
3.Using a recognised hose clamp, clamp hose to
prevent loss of brake fluid.
4.Disconnect rigid brake pipe from flexible hose,
seal exposed ends to prevent ingress of dirt.
5.Remove split [cotter] pin, retaining pins and
springs, withdraw pads. If refitting pads, identify
them for assembly to original locations.
6.Loosen bolts and remove caliper.
Repair
Do not separate caliper halves
7.Clean outer surfaces of caliper using aerosol
brake cleaner.
8.Using special tool LRT-70-500, clamp pistons in
inboard half of caliper. Gently, keeping fingers
clear, and withCAUTION,apply air pressure to
fluid inlet port to expel pistons. It is unlikely that
pistons will expel at same time, regulate rate
with a suitable piece of wood between
appropriate piston and caliper.
9.Finally remove pistons, identifying them with
their respective bores.
10.Remove wiper seal retainer by inserting a blunt
screwdriver between retainer and seal. Pry
retainer carefully from mouth of bore.
11.Taking care not to damage seal grooves, extract
wiper seal and fluid seal.
12.Clean bores, pistons and seal grooves using
clean brake fluid only. If caliper or pistons are
corroded, or their condition is not perfect, new
parts must be fitted.

BRAKES
15
REPAIR REAR BRAKE CALIPERS
Service repair no - 70.55.06
Service repair no - 70.55.17
Service tool:
LRT-50-700 - Piston clamp
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
Remove caliper
1.Loosen rear road wheel nuts. Jack up vehicle,
lower onto axle stands, remove wheels.
2.Using a recognised hose clamp, clamp flexible
brake hose above rear axle.
3.Remove brake pipe(s) from rear brake caliper(s).
4.Seal pipe ends to prevent ingress of dirt.
5.Remove retaining pins and springs and withdraw
pads. If same pads are to be refitted, identify
them for assembly in original positions.
6.Remove two bolts, withdraw caliper from axle.
Repair
Do not separate caliper halves
7.Clean outer surfaces of caliper with aerosol
brake cleaner.
8. WITH CAUTIONexpel pistons from their bores
by applying air pressure to fluid inlet port. It is
unlikely both pistons will expel at same time,
regulate rate with a suitable piece of wood
inserted between two pistons.
9.Finally, remove pistons keeping them identified
with their respective bores.
10.Remove wiper seal retainer by inserting a blunt
screwdriver between retainer and seal and pry
retainer carefully from mouth of bore.
11.Taking care not to damage seal grooves, extract
wiper seal and fluid seal.
12.Clean bores, pistons and particularly seal
grooves using clean brake fluid only. If caliper or
pistons are corroded or their condition is not
perfect new parts must be fitted.

SUPPLEMENTARY RESTRAINT SYSTEM
15
REPAIR AIRBAG MANUAL DEPLOYMENT
CAUTION: Deployment in the vehicle will
damage the steering wheel; if the vehicle
is not being scrapped deploy the module
away from the vehicle in accordance with the
separate procedure.
If a vehicle is to be scrapped and contains an
undeployed airbag module, the module must be
manually deployed. This operation should only be
carried out using the following recommended manual
deployment procedure.
Before deployment is started the deployment tool self
test procedure should be carried out.
Deployment tool SMD 4082/1 self test procedure
1.Insert BLUE and YELLOW connectors of tool
lead into corresponding sockets on face of tool.
2.Connect crocodile clips of second tool lead to
battery, RED to positive and BLACK to negative.
3.RED "READY" light should illuminate.
4.Press and hold both operating buttons.5.GREEN "DEFECTIVE" light should illuminate.
6.Release both operating buttons.
7.RED "READY" light should illuminate.
8.Disconnect tool from battery.
9.Disconnect blue and yellow connectors from tool
face sockets.
10.Self test now complete.
Deployment with module fitted to vehicle
These guidelines are written to aid authorised
personnel to carry out the safe disposal of the airbag
module when fitted to the vehicle.
WARNING: Only use the LAND ROVER
approved deployment equipment. Deploy
airbag module in a well ventilated
designated area. Ensure airbag module is not
damaged or ruptured before deploying.
1.Carry out deployment tool self test.
2.Release 2 turnbuckles securing lower panel to
dash, remove lower panel.