1995 LAND ROVER DISCOVERY ABS

R380
1
REPAIR R380 MANUAL GEARBOX
Service repair no - 37.20.02
Remove
WARNING: Where the use of a
transmission hoist is necessary, it is
absolutely essential to follow the
manufacturer's instructions to ensure safe and
effective use of equipment.
1.Install vehicle on a ramp [hoist].
2.Disconnect battery earth lead.
3.Remove centre console.
See CHASSIS AND
BODY, Repair, Centre Console
4.Remove sound insulation from top of
transmission tunnel.
5.Remove bolt and remove upper gear lever.
6.Remove screws securing gear selector lever and
high/low selector lever draft excluders.
7.Remove draft excluder clamp rings.
8.Remove handbrake cable clevis pin clip and
clevis pin.
9.Remove 'C' clip and cable adjuster.
10.Select low range to prevent gear lever fouling
tunnel when removing gearbox.
11.Remove bolt securing gearbox breather pipe clip
to cylinder block.
12.Remove bolts securing fan cowl to radiator.
13.Release fan cowl from radiator and lay over fan
blades.
14.Raise ramp [hoist].
15.Drain oil from main gearbox and transfer
gearbox.
See SECTION 10, Maintenance,
Under Vehicle Maintenance
16.Remove exhaust front pipe(s).See MANIFOLD
AND EXHAUST SYSTEM, Repair, Exhaust
System Complete
17.Release intermediate exhaust pipe(s) from
mountings and tie aside.
18.Remove bolts securing clutch slave cylinder.
19.Release slave cylinder from clutch housing and
collect spacer.
20.Mark propeller shaft drive flange relationships for
reassembly.
21.Disconnect front and rear propeller shafts from
transfer gearbox. Tie shafts aside.
22.Remove clamp and disconnect speedometer
cable from transfer gearbox.
23.Release handbrake cable from transmission
tunnel.
24.Temporarily support transmission in a way which
enables the crossmember to be removed and a
hoist cradle to be fitted.

REAR AXLE AND FINAL DRIVE
1
DESCRIPTION AND OPERATION DESCRIPTION
The welded steel rear axle casing houses a separate
spiral bevel type differential unit, which is off set to the
right of the vehicle centre line. The differential unit
drives the rear wheels via the axle shafts and fully
floating hubs which are mounted on tapered roller
bearings.
Lubrication
The differential is lubricated with oil and the hub
bearings with grease. The hub bearings are fittedwith inner and outer seals. The outer seals prevent
the differential oil mixing with the hub grease and the
inner seals prevent dirt ingress into the hub.
Ventilation
Ventilation of the hub bearings is through the outer oil
seals and the differential ventilation pipe, which
terminates at a high level.
The wheel hubs on axles with ABS brakes share the
same construction to non ABS axles except for the
addition of a sensor ring 11 on the brake disc 10.
Rear axle hub
1. Axle casing
2. Ventilation pipe
3. Axle shaft
4. Wheel studs and hub
5. Wheel bearing stub axle
6. Wheel bearings (2)7. Inner hub seal
8. Outer hub/axle shaft seal
9. Hub lock plate, thrust washer and nuts (2)
10. Brake disc
11. Sensor ring, ABS

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.

51REAR AXLE AND FINAL DRIVE
4
REPAIR Refit
10.Clean stub axle. Retract ABS sensor slightly
from sensor sleeve, if applicable
11.Fit hub assembly to stub axle.
12.Fit spacing washer.
13.Fit hub adjusting nut. Tighten to
61 Nm.
Back off adjusting nut 90°. Tighten to4 Nm.
This will give the required hub end float of
0,010mm
14.Fit a new lock washer.
15.Fit locknut. Tighten to61 Nm.
16.Tab over lock washer to secure adjusting nut
and locknut.
17.Using a new joint washer fit axle shaft to hub,
secure with five bolts. Tighten to
65 Nm.
18.Fit brake caliper. Tighten to82 Nm.
Secure brake pipes to axle casing.
19.If applicable, set ABS brakes sensor.
Push sensor in until it touches sensor ring then
rotate hub to set sensor.
20.Fit road wheel, remove axle stands and final
tighten road wheel nuts to
126 Nm.
21.Operate footbrake to locate brake pads before
driving vehicle.

REAR AXLE AND FINAL DRIVE
9
OVERHAUL REAR HUB ASSEMBLY
Service repair no - 61.15.13.
Overhaul
1.Remove rear hub assembly.
See Repair, Rear
Hub Assembly
2.Remove outer bearing.
3.Remove five nyloc nuts and withdraw ABS
sensor ring, if applicable.
4.Mark, for reassembly, position of hub to brake
disc.5.Remove five bolts and separate hub from brake
disc.
WARNING: A maximum of two road wheel
retaining studs can be renewed. Should
more studs be unserviceable fit new hub
with studs.
6.Remove grease seal and inner bearing from
hub.
7.Remove inner and outer bearing tracks.
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
11
OVERHAUL REAR STUB AXLE
Service repair no - 64.15.22.
STUB AXLE COMPONENTS
1. Rear axle shaft.
2. Stub axle to axle casing bolt.
3. Mudshield.
4. Stub axle.
5. Stub axle joint washer.
6. Axle case.
7. Sensor ABS.
Overhaul
1.Remove hub assembly.
See Repair, Rear Hub
Assembly
2.Remove six bolts from stub axle to axle casing.
3.Remove mudshield.
4.Remove stub axle and joint washer.
5.Remove rear axle shaft from axle casing.
Renew rear stub axle oil seal
6.Remove and discard oil seal. Lubricate seal and
lip with EP90 oil. Using special tool LST 138 fit
new oil seal lipside trailing so that seal is flush
with rear face of stub axle.
Refit
7.Fit new joint washer, stub axle and mudshield
with bolts. Tighten to
65 Nm.
8.Fit rear axle shaft avoid damaging stub axle
seal.
9.Refit rear hub assembly.
See Repair, Rear
Hub Assembly