1995 LAND ROVER DISCOVERY Workshop Manual

REAR SUSPENSION
1
DESCRIPTION AND OPERATION AXLE LOCATION
Longitudinal location of the rear axle is by solid round section steel link arms and a forged "A" frame, upper link
assembly, which is secured to a chassis cross member and provides transverse control. Long travel coil springs
and hydraulic shock absorbers provide the springing for each wheel.
Rear axle suspension
1. "A" frame, upper link assembly - transverse location
2. Lower link assembly - longitudinal location
3. Coil springs
4. Shock absorber

REAR SUSPENSION
1
REPAIR REAR ROAD SPRING
Service repair no - 64.20.01
Remove
1.Loosen rear road wheel retaining nuts.
2.Support chassis on stands and remove wheels.
3.Support rear axle weight with jack.
4.Disconnect shock absorbers at one end.
5.Position coil spring compressor correctly on road
spring.
6.Compress spring evenly to facilitate removal.
7.Lower axle to free road spring from upper seat.
CAUTION: Avoid lowering axle further than
rear brake flexible hose will allow.
8.Remove spring retainer plate.
9.Withdraw road spring, and spring isolator.
10.Lift off spring seat.
Refit
11.Reverse removal procedure.REAR SHOCK ABSORBER
Service repair no - 64.30.02.
Remove
1.Loosen road wheel retaining nuts.
2.Support chassis on stands. Remove road wheel
and support rear axle weight with jack.
3.Remove fixings and withdraw shock absorber
from axle bracket.
4.Remove upper fixings.
5.Withdraw shock absorber.
6.If required remove mounting bracket
7.If required remove mounting rubbers.
Refit
8.Reverse removal procedure.

64REAR SUSPENSION
2
REPAIR BUMP STOP
Service repair no - 64.30.15.
Remove
1.Remove fixings.
2.Remove bump stop.
Refit
3.Position bolts in slots in bracket.
4.Fit bump stop secure with washer and nuts.SUSPENSION LINK UPPER
Service repair no - 64.35.44.
Remove
1.Support rear of chassis on stands, allow axle to
hang freely.
2.Remove fixings, upper link bracket to frame.
3.Remove fixings, upper links to pivot bracket.
4.Remove upper link complete with frame bracket.
5.Remove bolt.
6.Separate link from bracket.

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.

64REAR SUSPENSION
4
REPAIR ANTI-ROLL[SWAY] BAR ASSEMBLY REAR
Service repair no - 64.35.08.
KEY
1. Anti-roll[sway] bar
2. Rubber bush
3. Strap
4. Nut, bolt, washer5. Nut and washer
6. Ball joint link arm
7. Bolt and washer
8. Castellated nut and cotter pin
Remove
1.Note for reassembly, position of rubber bushes
on anti-roll bar.
2.Remove four nuts, bolts and washers securing
two bush straps.
3.Remove nuts, bolts, washers and rubber bushes
from the ball joint links and remove anti-roll bar.Refit
4.Position rubber bushes on anti-roll bar. Fit joint
towards axle.
5.Fit anti-roll bar with two straps. Ensure ball joint
link arms point down as shown. Loosely fit, bolts,
washers and new nyloc nuts.
6.Fit bolt, washers and rubber bushes. Fit anti-roll
bar to ball joint links. Tighten to
68Nm.
7.Tighten nuts securing straps to30Nm.

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