1995 LAND ROVER DISCOVERY Workshop Manual

FRONT AXLE AND FINAL DRIVE
3
OVERHAUL FRONT STUB AXLE, CONSTANT VELOCITY JOINT
AND SWIVEL PIN HOUSING NON ABS
Service repair no - 60.15.43.
Remove stub axle, axle shaft and constant
velocity joint.
1.Remove front hub assembly.
See Repair,
Front Hub Assembly
2.Drain swivel pin housing and refit plug.
3.Remove six bolts retaining stub axle to swivel
housing.
4.Remove mud shield.
5.Remove stub axle and joint washer.
6.Pull out axle shaft and constant velocity joint
from axle casing.
Remove constant velocity joint from axle shaft
7.Hold axle shaft firmly in a soft jawed vice.
8.Using a soft mallet drive constant velocity joint
from shaft.
9.Remove circlip and collar from axle shaft.
Constant velocity joint
10.Mark positions of constant velocity joint, inner
and outer race and cage for reassembly.
11.Swivel cage and inner race to remove balls.

54FRONT AXLE AND FINAL DRIVE
4
OVERHAUL 12.Examine all components in particular inner and
outer track, cage balls and bearing surfaces for
damage and excessive wear.
13.Maximum acceptable end-float on assembled
joint 0,64mm. Renew if worn or damaged.
Lubricate with a recommended oil during
assembly.
Fit constant velocity joint to axle
14.Fit collar and a new circlip.
15.Engage constant velocity joint on axle shaft
splines and using a soft mallet, drive joint in fully.
Renew stub axle,thrust ring, oil seal and bearing
16.Drill and chisel off thrust ring taking care to avoid
damaging stub axle.
17.Remove bearing and oil seal using special tool
LRT-37-004 and slide hammer LRT-99-004.
Ensure lip of tool locates behind bearing to to
drive it out.
18.Repeat instruction for removal of oil seal.
19.Lubricate seal and lip with EP90 oil and with
cavity side leading press in a new oil seal using
special tool LRT-54-004.
20.Using special tool LRT-54-005, fit bearing with
its part number visible when fitted, and flush with
end face of stub axle.
21.Press fit a new thrust ring onto stub axle.

FRONT AXLE AND FINAL DRIVE
5
OVERHAUL Swivel pin housing
22.Remove bolts securing oil seal retaining plate
and joint washer. Release assembly from swivel
pin housing.
NOTE: Removal of oil seal and retaining
plate is achieved when swivel bearing
housing is removed.
23.Remove two bolts, retaining lower swivel pin to
housing.
24.Remove brake disc shield bracket.
25.tap lug to remove lower swivel pin and joint
washer.
26.Remove two bolts retainin brake hose bracket
and top swivel pin.
27.Remove bracket, top swivel pin and shims.
28.Remove swivel pin housing while retrieving
lower and upper bearings.
Swivel bearing housing
29.Remove lower bearing track from swivel bearing
housing.
NOTE: Use upper bearing opening to gain
access to lower bearing track.
30.Remove seven bolts retaining swivel bearing
housing to axle case.
31.Remove inner oil seal from back of housing.
32.Remove top bearing track from swivel bearing
housing.
NOTE: Use lower bearing opening to gain
access to upper bearing track.
33.If worn, pitted or damaged, renew housing.
34.Fit upper and lower bearing tracks into swivel
bearing housing.
CAUTION: Ensure bearing tracks are fitted
square or damage could occur.
35.With seal lips trailing, fit swivel housing inner oil
seal into rear of housing. Grease seal lips.Fit swivel pin housing
36.Coat swivel bearing housing to axle casing bolts
with Loctite 270 or equivalent.
37.Coat both sides of joint washer with a sealing
compound. Position swivel bearing housing to
axle mating face.
38.Place retaining plate, joint washer and oil seal
over axle flange ready for assembly.
39.Fit swivel bearing housing to axle flange with
seven bolts. Tighten to
73 Nm.
40.Grease and fit upper and lower swivel pin taper
roller bearings.
41.Position swivel pin housing over swivel bearing
housing.
42.Coat joint washer both sides with sealing
compound and position on lower swivel pin.
43.Loosely fit brake shield bracket plus lower swivel
pin with lug outboard to swivel pin housing.
44.Loosely fit top swivel pin plus existing shims and
brake hose bracket to swivel pin housing.
45.Apply Loctite 270 or equivalent to lower swivel
pin bolts. Tighten to
78 Nmbend over lock
tabs.
46.Tighten top swivel pin bolts to
78 Nm.

54FRONT AXLE AND FINAL DRIVE
6
OVERHAUL Swivel assembly components
1. Swivel pin housing
2. Top swivel pin and brake hose bracket
3. Upper and lower swivel pin bearings
4. Shim
5. Retaining plate and washer
6. Oil seal
7. Joint washer
8. Swivel bearing housing
9. Joint washer
10. Lower swivel pin
11. Mudshield bracket
12. Swivel housing inner oil sealCheck and adjust preload on bearings
NOTE: Swivel housing oil seal and axle
should not be fitted.
47.Attach a spring balance to ball joint bore and pull
balance to determine effort required to turn
swivel pin housing.
Resistance, once initial inertia has been
overcome, should be1.16 to 1.46 kg.Adjust by
removing or adding shims to top swivel pin.
48.When setting is correct remove top swivel bolts,
apply Loctite 270 or equivalent. Refit to
78 Nm,
and bend over lock tabs.
49.Apply recommended grease between lips of
swivel oil seal.
50.Fit oil seal, joint washer and retaining plate with
seven bolts and spring washers to
11 Nm.
51.Fit tie rod and drag link and secure with new
cotter pins. Tighten to
40 Nm.
52.Fit brake disc shield.
53.Loosely fit lock stop bolt and nut.
54.Apply a recommended grease between lips of
swivel housing oil seal.
55.Secure oil seal with retaining plate and securing
bolts. Tighten to
11 Nm.
56.Fit track-rod and drag link and secure with new
cotter pins.
57.Loosely fit lock stop bolt for later adjustment.
58.Fit brake disc shield.

FRONT AXLE AND FINAL DRIVE
7
OVERHAUL Fit driveshaft and stub axle
59.Insert axle shaft, and when differential splines
are engaged, push assembly in fully.
CAUTION: Take care not to damage axle
shaft oil seals.
60.Place a new joint washer in position on swivelpin
housing to stub axle mating face. Coat threads
of stub axle bolts with Loctite 270.
61.Fit stub axle with flat at 12 o'clock position.
CAUTION: Ensure that constant velocity
joint bearing journal is butted against
thrust ring on stub axle. Before stub axle
is secured.
62.Place mud shield in position and secure stub
axle to swivel pin housing with six bolts and
tighten evenly to
65 Nm.
63.Fit brake jump hoses to brake jump hose
bracket.
64.Fit front hub complete assembly.
See Repair,
Front Hub Assembly
65.Check swivel pin housing oil drain plug is fitted.
66.Fill swivel assembly to correct level, with new oil.
See SECTION 10, Maintenance, Under
Vehicle Maintenance
67.Set steering lock stop bolts to provide a
clearance of 20mm.
See STEERING,
Adjustment, Steering Lock Stops
FRONT STUB AXLE, CONSTANT VELOCITY JOINT
AND SWIVEL PIN HOUSING ABS
Service repair no - 60.15.43.
Remove stub axle, axle shaft and constant
velocity joint.
1.Remove front hub assembly.
See Repair,
Front Hub Assembly
2.Drain swivel pin housing and refit plug.
3.Remove six bolts retaining stub axle to swivel
housing.
4.Remove mud shield.
5.Remove stub axle and joint washer.
6.Pull out axle shaft and constant velocity joint
from axle casing.

54FRONT AXLE AND FINAL DRIVE
8
OVERHAUL Remove constant velocity joint from axle shaft
7.Hold axle shaft firmly in a soft jawed vice.
8.Using a soft mallet drive constant velocity joint
from shaft.
9.Remove circlip and collar from axle shaft.
Constant velocity joint
10.Mark positions of constant velocity joint, inner
and outer race and cage for reassembly.
11.Swivel cage and inner race to remove balls.
12.Examine all components in particular inner and
outer track, cage balls and bearing surfaces for
damage and excessive wear.
13.Maximum acceptable end-float on assembled
joint 0,64mm. Renew if worn or damaged.
Lubricate with a recommended oil during
assembly.
Fit constant velocity joint to axle
14.Fit collar and a new circlip.
15.Engage constant velocity joint on axle shaft
splines and using a soft mallet, drive joint in fully.
Renew stub axle,thrust ring, oil seal and bearing
16.Drill and chisel off thrust ring taking care to avoid
damaging stub axle.
17.Remove bearing and oil seal using special tool
LRT-37-004 and slide hammer LRT-99-004.
Ensure lip of tool locates behind bearing to to
drive it out.
18.Repeat instruction for removal of oil seal.

FRONT AXLE AND FINAL DRIVE
9
OVERHAUL 19.Lubricate seal and lip with EP90 oil and with
cavity side leading press in a new oil seal using
special tool LRT-54-004.
20.Using special tool LRT-54-005, fit bearing with
its part number visible when fitted, and flush with
end face of stub axle.
21.Press fit a new thrust ring onto stub axle.
Swivel pin housing assembly
22.Remove brake disc shield bracket.
23.Disconnect track-rod end ball joint from housing.
24.Disconnect drag-link ball joint.
25.Disconnect jump hoses from brake jump hose
bracket.
26.Remove ABS brake sensor.
27.Remove six bolts securing oil seal and retaining
plate to swivel pin housing. Prise seal from
swivel pin housing.
NOTE: Oil seal and retaining plate cannot
be removed until swivel pin bearing
housing is removed.
28.Remove two screws securing brake
damper/shield bracket and lower swivel pin to
housing.
29.Withdraw lower swivel pin and joint washer by
tapping protruding lug.
30.Remove top swivel pin retaining bolts complete
with brake jump hose bracket.
31.Remove top swivel pin and shims.
32.Remove swivel pin housing while retrieving
lower taper bearing.
Swivel pin bearing housing
33.Remove seven bolts securing swivel pin bearing
housing to axle case.
34.Remove and discard oil seal and joint washer.
35.Remove lower swivel pin bearing track.
36.Remove top swivel pin bush housing assembly.
Discard two thrust washers and bearing.
37.If worn, pitted or damaged, renew swivel pin
bearing housing.
38.Fit a new lower swivel pin bearing track.
39.Fit a new bush and bush housing. Ensure
relieved lip of bush housing faces towards rear,
as shown.

54FRONT AXLE AND FINAL DRIVE
10
OVERHAUL
40.With seal lips trailing press axle shaft oil seal
flush into rear of housing. Grease lips.
41.Fit new thrust washers and bearing into top
swivel pin bush.
42.Hang swivel pin bearing housing oil seal and
retainer plate over back of housing. Ensure they
are in correct assembly order.
43.Fit a new joint washer and secure swivel pin
bearing housing to axle. Starting with top fixing
dowel bolt. Tighten to
72Nm.
Fit swivel pin housing
44.Grease and fit lower swivel pin bearing to
bearing housing.
45.Place swivel pin housing in position over swivel
pin bearing housing.
46.Using a new joint washer, fit lower swivel pin
with lip outboard. Do not secure with screws at
this stage.
47.Fit a new sensor bush and new oil seal, lip side
leading to top swivel pin.
48.Lubricate with a recommended oil and fit top
swivel pin with existing shims.
49.Coat threads of top swivel pin bolts with Loctite
542. Fit bolts and jump hose bracket (do not
tighten).50.Coat threads of lower swivel pin screws with
Loctite 270 and fit, together with damper and
shield bracket. Tighten to
25 Nm.
51.Tighten top swivel pin and brake jump hose
bracket securing bolts to
65 Nm.
Check and adjust preload on bearings
52.The preload on bearings to be0,25 to 0,30 mm,
withoutswivel housing oil seal and axle fitted,
and reading from centre of swivel pin. The
torque required to turn swivel assembly from
lock to lock to be
2.0 to 2.8 Nm.Adjust by
removing or adding shims as necessary.
53.To take a reading use special tool LRT-57-024
torque test adaptor, with a torque wrench and
extension as shown.
54.Apply a recommended grease between lips of
swivel housing oil seal.
55.Secure oil seal with retaining plate and securing
bolts. Tighten to
11Nm.
56.Fit track-rod and drag link and secure with new
cotter pins.
57.Loosely fit lock stop bolt for later adjustment.
58.Fit brake disc shield.