1999 LAND ROVER DISCOVERY wheel bolts

FRONT AXLE
54-10 REPAIRS
9.Remove oil seal from axle casing.Refit
1.Clean drive shaft oil seal recess, oil seal
running surface, wheel hub and swivel hub
mating faces.
2.Lubricate oil seal lip and running surface with
clean differential oil.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Using tool LRT-54-012 and tool LRT-99-003,
fit new drive shaft oil seal to axle casing.
4.Apply anti-seize compound to wheel hub and
steering knuckle mating faces.
5.Ensure ABS harness is located in cut out in
steering knuckle.
6.Fit drive shaft and wheel hub to axle casing and
align wheel hub with steering knuckle. Fit wheel
hub bolts and tighten to 100 Nm (74 lbf.ft).
7.Connect ABS sensor multiplug and secure
harness to harness bracket and brake hose.
8.Fit front brake disc.

+ BRAKES, REPAIRS, Brake disc -
front.
9.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
10.Remove stand(s) and lower vehicle.
11.Check differential oil level.

+ MAINTENANCE, PROCEDURES,
Front and rear axle.

STEERING
57-6 DESCRIPTION AND OPERATION
Tilt adjustment
The column tilt adjuster lever mechanism is located on the LH side of the steering column and allows the upper column
tube, nacelle and steering wheel assemblies to be tilted up or down a maximum of 7.5° or 47 mm (NAS vehicles have
a smaller range of movement than the ROW vehicles).
The pawl of the mechanism is attached to the lower column and is allowed to pivot, a toothed quadrant is fixed to the
upper column tube.
When the lever on the LH side of the steering column is raised the mechanism releases the pawl from the toothed
quadrant, this allows the column to be moved. When the lever is released two return springs pull the pawl into
engagement with the toothed quadrant.
Steering column lock (All except NAS)
The steering column lock houses the ignition switch, ignition illumination light ring, key lock barrel and the alarm
passive coil. The steering lock is attached to the upper column with two shear bolts. The bolts are tightened to a
torque which shears off the heads of the bolts preventing easy removal of the steering lock.
The steering lock operates by a bolt, which emerges when the ignition key is turned to position 'O' and the ignition key
removed. The bolt engages in a lock collar located on the upper shaft in the upper column tube. The lock collar is
attached to the upper shaft by a 'wave form' interference ring. If a high torque is applied via the steering wheel with
the lock engaged, the lock collar will slip on the upper shaft. This prevents damage to the steering lock, yet still
prevents the vehicle from being driven.
Steering column lock (NAS only)
The steering column lock houses the ignition switch, ignition illumination light ring, key lock barrel and the alarm
passive coil. The steering lock is attached to the upper column with two shear bolts. The bolts are tightened to a
torque which shears off the heads of the bolts preventing easy removal of the steering lock.
The steering column lock operates by a bolt, which emerges when the ignition key is turned to position 'O' and the
ignition key removed. The bolt engages in a groove machined into the upper shaft in the column tube.
Steering wheel
The steering wheel comprises a cast centre and wire frame onto which the soft polyurethane foam is moulded. The
steering wheel is located on the upper column shaft by a spline and is secured with a nut. A remote radio control switch
(if fitted) is located on the LH side of the steering wheel, a cruise control switch may be located on the RH side. Horn
switches are located on each side of the centre of the steering wheel and protrude through the airbag module cover.
Both switches are connected by wires to the rotary coupler connector.
Intermediate shaft
One end of the intermediate shaft is attached to the steering column lower shaft by a splined universal joint and a bolt,
the universal joint is part of a rubber coupling assembly. The rubber coupling assembly is covered by a heat shield
and connects to the lower section of the intermediate shaft via a decouple joint. The rubber coupling reduces the
shocks felt by the driver through the steering wheel. A second universal joint on the other end of the intermediate shaft
is held in by a bolt. The universal joint is splined and engages with the splined rotor (input) shaft of the steering box.
The decouple joint consists of a metal plate that has open ended slots, the plate is bolted through the slots into the
other half of the decouple joint. The top half of the decouple joint has a slot that accepts the lower section of the
intermediate shaft. The slotted metal plate clamps the lower section of the intermediate shaft to the top section. An
indicator clip is installed between the slotted metal plate and the top half of the decouple joint.
If the intermediate shaft is compressed in an accident, the slotted metal plate in the decouple joint will disengage if
sufficient force is applied to the front end of the shaft. If the forces involved do not disengage the shaft, the red
indicator clip located in the decouple joint will break off if the shaft moves. The intermediate shaft cannot be repaired
and must be replaced as an assembly if accident damage occurs.

STEERING
57-8 DESCRIPTION AND OPERATION
Steering box
The steering box is located behind the first cross member of the chassis and is secured to the chassis rail with four
bolts. The steering box is of the worm and roller type and has a rotary control valve. The steering box is connected to
the steering knuckles of the front road wheels by the drop arm, drag link and track rod. The steering box is lubricated
by the hydraulic fluid in the housing. The input shaft is attached to the steering wheel via the intermediate shaft and
steering column. The drop arm is secured to the output shaft with a nut and tab washer. A ball joint allows movement
between drop arm and drag link, the ball joint is secured with a locknut. The steering box requries approximately 3.5
turns from lock to lock.
As a maintenance aid, an alignment bolt can be used to lock the drop arm at the steering box centre position. The bolt
fits in a groove in the rear face of the drop arm and screws in to a threaded hole on the bottom of the steering box
housing.
Cross section through steering box
1Relief valve stop 2 off
2Relief valve 2 off
3Piston
4Rack
5Housing
6Output shaft
7Roller
8Valve rotor9Torsion bar
10Input shaft
11Pin
12Valve sleeve
13Course spline
14Worm gear
15Spline (worm gear to torsion bar)

STEERING
57-18 ADJUSTMENTS
Hydraulic system - bleed
$% 57.15.02
Bleed
1.Clean PAS fluid reservoir around filler cap and
fluid level indicators.
2.Remove filler cap from PAS fluid reservoir. If
necessary, fill PAS fluid reservoir to upper level
indicator with recommended fluid.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
CAUTION: Ensure no dirt is allowed to enter
the steering reservoir when the cap is
removed.
3.Start engine and run to normal operating
temperature.
4.Position container to catch fluid spillage from
steering box.
5.With engine at idle speed, and an assistant
turning the steering from lock to lock, loosen
bleed screw on top of steering box. Keep PAS
fluid reservoir topped up and allow all air to
bleed from system. When fluid from bleed
screw is free of air, tighten bleed screw.
CAUTION: Do not hold steering at full lock
for longer than 10 seconds.
6.Stop engine.
7.Clean spilled PAS fluid from steering box and
surrounding area.
CAUTION: Power steering fluid will damage
paint finished surfaces. If spilled,
immediately remove fluid and clean area
with water.
8.Check fluid level in PAS fluid reservoir and fill to
upper level mark. If fluid is aerated, wait until
fluid is free from bubbles.
9.Fit PAS fluid reservoir filler cap.
Steering linkage - centralise
$% 57.35.05
The following procedure assumes that the front
wheel alignment is correctly adjusted.
Adjust
1.Raise front of vehicle, and position the road
wheels at straight ahead.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove nut securing drag link to drop arm.
Using tool LRT-57-036 break taper joint and
release drag link from drop arm.
3.Fit centralising bolt to steering box and ensure
that front road wheels are in the straight ahead
position.
4.Loosen clamp bolts on drag link.

STEERING
ADJUSTMENTS 57-19
5.Adjust drag link so that taper joint is centralised
in drop arm, then tighten drag link clamp bolts:
Tighten M8 bolts to 22 Nm (16 lbf.ft) and M10
bolts to 33 Nm (24 lbf.ft).
6.Connect drag link to drop arm and tighten nut to
80 Nm (59 lbf.ft).
7.Remove steering box centralising bolt.
8.Remove stand(s) and lower vehicle.
9.Road test the vehicle and check that the
steering wheel is centralised. If steering wheel
is not centralised, proceed as follows.
10.Slacken drag link adjuster clamp bolts.
11.Without disconnecting drag link from drop arm,
adjust the length of the drag link to bring the
steering wheel to the central position.
CAUTION: Repositioning the steering wheel
on its splines cannot correct small (less
than 5°) errors in steering wheel alignment.
Always rectify small errors in alignment by
adjusting the drag link as detailed above,
ensuring that steering box centralisation is
maintained.
12.Tighten drag link clamp bolts: Tighten M8 bolts
to 22 Nm (16 lbf.ft) and M10 bolts to 33 Nm (24
lbf.ft)
Wheel alignment - front
$% 57.65.01
The following is the only wheel alignment equipment
which has been approved.
lBeissbarth ML 4600 wheel alignment computer
(6 sensor).
lBeissbarth ML 4600-8 wheel alignment
computer (8 sensor).
lBeissbarth ML 4000 wheel alignment computer
(8 sensor wireless).
lHunter S411-14.
Check
1.Ensure tyre pressures are correct and vehicle
is at kerbside weight.
2.Roll vehicle backwards and forwards to relieve
stresses in steering and suspension.
3.Ensure road wheels are positioned straight
ahead.
4.Ensure that wheel alignment equipment is
properly calibrated.
5.Following the equipment manufacturer's
instructions, measure the front wheel
alignment. Compare with the figures given in
General Data.

+ GENERAL DATA, Steering.
Adjust
1.Loosen track rod and adjuster clamp bolts.
2.Rotate adjuster to obtain correct alignment.

+ GENERAL DATA, Steering.
3.Tighten track rod and adjuster clamp bolts:
Tighten M8 bolts to 22 Nm (16 lbf.ft) and M10
bolts to 33 Nm (24 lbf.ft).
4.Recheck front wheel alignment.

STEERING
REPAIRS 57-27
REPAIRS
Power steering box - V8
$% 57.10.01
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove front road wheel.
3.Ensure steering wheel is centralised and fit
centralising bolt to steering box. Remove key
from steering lock and engage column lock.
4.Remove 3 bolts securing intermediate shaft
and universal joint.
5.Push intermediate shaft upwards, release and
remove universal joint.
CAUTION: Do not turn the steering wheel
with the intermediate shaft or universal joint
disconnected as damage to the rotary
coupler and the steering wheel switches
may occur.
6.Position container to catch oil spillage.

STEERING
REPAIRS 57-29
12. RH drive models with ACE: Position ACE
control arms to access steering box bolts.
13.With assistance remove 4 securing bolts and
remove steering box.
14.Remove centralising bolt from steering box. Refit
1.Fit centralising bolt to steering box.
2. With assistance, position steering box, fit bolts
and tighten to 90 Nm (66 lbf.ft).
3. RH drive models with ACE: Ensure washer is
in place on lower ball joint of anti-roll bar link,
then connect lower ball joint to axle. Tighten nut
to 100 Nm (74 lbf.ft).
4.Position drag link, fit nut and tighten to 80 Nm
(59 lbf.ft).
5.Position Panhard rod, fit bolt and nut and
tighten to 230 Nm (170 lbf.ft).
6.Clean PAS pipe ends and 'O' ring recess.
7.Lubricate new 'O' rings for PAS pipes with clean
PAS fluid.
8.Fit 'O' rings to PAS pipes and position pipes in
steering box. Fit PAS pipe bracket and tighten
bolt to 22 Nm (16 lbf.ft).
9. RHD models: Fit oil filter and housing:
lClean oil filter housing and engine mating
faces.
lLubricate new 'O' ring with clean engine oil
and fit to housing.
lPosition oil filter housing and tighten bolts to
9 Nm (7 lbf.ft).
10.Ensure steering wheel is centralised. Fit
universal joint between steering box and
intermediate shaft and tighten bolts to 25 Nm
(18 lbf.ft).
11.Remove centralising bolt from steering box.
12.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft)..
13.Remove stand(s) and lower vehicle.
14.Check and top up engine oil.
15.Bleed PAS system.

+ STEERING, ADJUSTMENTS,
Hydraulic system - bleed.
16.Centralise steering linkage

+ STEERING, ADJUSTMENTS,
Steering linkage - centralise.

STEERING
57-30 REPAIRS
Power steering box - LHD - diesel
$% 57.10.01
Remove
1.Remove battery cover.
2.Disconnect battery earth lead.
3.Drain cooling system.

+ COOLING SYSTEM - Td5,
ADJUSTMENTS, Drain and refill.
4.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
5.Remove LH front road wheel.
6.Ensure steering wheel is centralised, remove
key from steering lock and engage column lock.
7.Fit centralising bolt to steering box.
8.Loosen 2 clips securing intercooler to turbo
hose. Remove hose.9.Remove 3 bolts securing intermediate shaft
and universal joint.
10.Push intermediate shaft upwards, release and
remove universal joint.
CAUTION: Do not turn the steering wheel
with the intermediate shaft or universal joint
disconnected as damage to the rotary
coupler and the steering wheel switches
may occur.
11.Position container below PAS pipes to catch
fluid spillage.