1999 LAND ROVER DISCOVERY Workshop Manual

FRONT SUSPENSION
ADJUSTMENTS 60-25
ADJUST ME NTS
ACE hydraulic system bleeding
$% 60.60.13
Introduction
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Check
1.Check the ACE system fluid level.

+ FRONT SUSPENSION,
ADJUSTMENTS, Fluid level check - ACE
system.
Bleed
1.With vehicle on ramp, connect TestBook and
follow bleed procedure as described.
Fluid level check - ACE system
$% 60.60.14
Introduction
CAUTION: The ACE hydraulic system is
extremely sensitive to the ingress of dirt or
debris. The smallest amount could render the
system unserviceable. It is imperative that the
following precautions are taken.
lACE components are thoroughly cleaned
externally before work commences;
lall opened pipe and module ports are
capped immediately;
lall fluid is stored in and administered
through clean containers.
Check
1.Clean reservoir around fluid level marks.
2.Visually check fluid level through side of
reservoir. Fluid level must be between upper
and lower fluid level marks.
Top-up
1.Clean reservoir around filler cap.
2.Remove filler cap from reservoir and fill to
upper fluid level mark with recommended fluid.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS, Fluids.
3.Fit filler cap to reservoir
4.Start and run engine for 2 minutes to circulate
fluid.
5.If necessary, top-up reservoir to upper fluid
level mark.

FRONT SUSPENSION
REPAIRS 60-27
REPAIRS
Bushes - Panhard rod
$% 60.10.07
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 2 nuts and bolts securing Panhard rod
to axle and chassis.
3.Remove Panhard rod from vehicle.
4.Use tool LRT-60-013 fitted with LRT-60-013/1
and LRT-60-013/3 to press out bushes from
Panhard rod. Refit
1.Clean bush locations in Panhard rod.
2.Use tool LRT-60-013 fitted with LRT-60-013/1
and LRT-60-013/2 to press new bushes into
Panhard rod. Ensure pressure is applied to
the outer edge of the bush, not the rubber
inner.
3.Position Panhard rod to axle and chassis.
4.Fit bolts securing Panhard rod but do not
tighten at this stage.
5.Remove stand(s) and lower vehicle.
6.Tighten bolts securing Panhard rod to 230 Nm
(170 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.

FRONT SUSPENSION
60-28 REPAIRS
Ball joint - upper - steering knuckle
$% 60.15.02
CAUTION: Each ball joint can be replaced up to
three times before the axle yoke bore becomes
oversize. Before commencing work, thoroughly
clean surface of joint and check for yellow paint
marks approx. 12 mm (0.5 in) wide. If 3 marks are
found, the axle case must be renewed.
Remove
1.Remove steering knuckle.

+ FRONT SUSPENSION, REPAIRS,
Steering knuckle.
2.Support the chassis on stands.
3.Support the front axle on stands.
4.Remove 2 nuts securing anti-roll bar lower links
to front axle, use a 16 mm spanner to prevent
link joint from turning.
5.Remove 2 bolts securing each front damper to
axle.
6.Remove 8 bolts securing chassis crossmember
and remove crossmember.
7.Remove bolt securing brake hose and ABS
sensor harness bracket to axle.
8.Lower the front axle, release front spring from
damper and remove front spring.9.Fit tool LRT-54-008/22 to tool LRT-54-008.
10.Fit tool LRT-54-008/4 to tool LRT-54-008, and
secure with screw.
11.Fit tool LRT-54-008 with all attachments to
upper ball joint.
12.Fit tool LRT-54-008/5 to the top of the ball
joint.
13.Press upper ball joint from axle. When ram lead
screw reaches the end of its stroke, retract the
lead screw and screw the ram further into the
tool. Repeat the operation until the ball joint is
released from the axle.
14.Dismantle the tools.

FRONT SUSPENSION
REPAIRS 60-29
Refit
1.Clean upper ball joint location and surrounding
area of axle yoke.
2.Apply a 12 mm (0.5 in) wide yellow paint stripe
on axle yoke, adjacent to upper ball joint
location.
3.Fit tool LRT-54-021 to tool LRT-54-008, and
secure with the screw.
4.Fit tool LRT-54-008/7 to tool LRT-54-008 and
position tool assembly over ball joint and axle.
5.Align tool assembly and press upper ball joint
into axle yoke.
CAUTION: Damage to the joint boot will
result if the tool is not correctly aligned
during the fitting procedure.
6.Remove tools from axle yoke.
7.Clean the spring seats.
8.Position spring over damper and locate in cut-
out in spring seat.
9.Raise the front axle, fit bolts securing dampers
to front axle and tighten to 45 Nm (33 lbf.ft).
10.Fit chassis crossmember, fit bolts and tighten to
25 Nm (18 lbf.ft).
11.Locate brake hose bracket and tighten bolt to
20 Nm (15 lbf.ft).
12.Position anti-roll bar links to the axle, fit the nuts
and tighten to 100 Nm (74 lbf.ft).
13.Fit steering knuckle.

+ FRONT SUSPENSION, REPAIRS,
Steering knuckle.
Ball joint - lower - steering knuckle
$% 60.15.03
CAUTION: Each ball joint can be replaced up to
three times before the axle yoke bore becomes
oversize. Before commencing work, thoroughly
clean surface of joint and check for yellow paint
marks approx. 12 mm (0.5 in) wide. If 3 marks are
found, the axle case must be renewed.
Remove
1.Remove steering knuckle.

+ FRONT SUSPENSION, REPAIRS,
Steering knuckle.
2.Fit tool LRT-54-008/22 to tool LRT-54-008.
3.Fit tool LRT-54-008/24 to tool LRT-54-008 and
secure with screw.
4.Fit tool LRT-54-008/23 to underside of lower
ball joint.
5.With assistance, fit tool LRT-54-008 assembly
to lower ball joint.
6.Press ball joint from axle. When ram lead
screw reaches the end of its stroke, retract the
lead screw and screw the ram further into the
tool. Repeat the operation until the ball joint is
released from the axle.
7.Remove tools and the lower ball joint from axle
yoke.

FRONT SUSPENSION
60-30 REPAIRS
Refit
1.Clean lower ball joint location and surrounding
area of axle yoke.
2.Apply a 12 mm (0.5 in) wide yellow paint stripe
on axle yoke, adjacent to lower ball joint
location.
3.Fit tool LRT-54-022 to tool LRT-54-008 and
secure with screw.
4.Fit tool LRT-54-022 and tool LRT-54-008 to
lower ball joint location on axle yoke.
5.Fit new lower ball joint to tool LRT-54-008/14.
6.Fit LRT-54-008/14 and lower ball joint to LRT-
54-008, with lower ball joint positioned on axle
yoke.
7.Align tool assembly and press lower ball joint
into axle yoke.
CAUTION: Damage to the joint boot will
result if the tool is not correctly aligned
during the fitting procedure.
8.Remove tools from axle yoke
9.Fit steering knuckle.

+ FRONT SUSPENSION, REPAIRS,
Steering knuckle.
Steering knuckle
$% 60.15.19
Remove
1.Remove wheel hub.

+ FRONT SUSPENSION, REPAIRS,
Wheel hub.
2.Remove 3 bolts securing mudshield and
remove mudshield.
3.Remove 2 nuts securing track rod and (if
applicable) drag link to steering knuckle.
4.Break taper joints using LRT-57-036, then
position track rod and drag link aside.

FRONT SUSPENSION
REPAIRS 60-31
5.Remove 2 nuts securing ball joints to steering
knuckle.
6.Break taper joints using LRT-54-027 and
remove steering knuckle.
7.Remove tension collet from steering knuckle.
8.Remove drive shaft oil seal from axle casing.Refit
1.Clean taper bores in steering knuckle and
tension collet.
2.Fit tension collet into steering knuckle and
tighten to 5 Nm (3.7 lbf.ft).
3.Clean ball joint tapers and taper seats.
4.Position steering knuckle to axle yoke. Fit
upper ball joint nut and tighten to 110 Nm (81
lbf.ft). Fit lower ball joint nut and tighten to 135
Nm (100 lbf.ft).
5.Clean track rod and (if applicable) drag link
tapers and taper seats.
6.Connect track rod and drag link to steering
knuckle. Fit track rod and drag link nuts and
tighten to 80 Nm (59 lbf.ft).
7.Clean mudshield and steering knuckle mating
faces. Position mudshield, fit bolts and tighten
to 10 Nm (7 lbf.ft).
8.Fit wheel hub.
+ FRONT SUSPENSION, REPAIRS,
Wheel hub.