1999 LAND ROVER DISCOVERY Workshop Manual

FRONT SUSPENSION
60-32 REPAIRS
Road spring - front
$% 60.20.11
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.Support vehicle under chassis.
3.Remove front road wheels.
4.Support weight of front axle.
5.Remove 2 nuts securing anti-roll bar links to
front axle and disconnect links from axle.
6.Remove 2 bolts securing each damper to front
axle.
WARNING: Make sure the axle cannot move
when the damper is disconnected. The
damper limits the downward movement of
the axle. If the axle is not restrained,
disconnecting the damper will allow
unrestricted movement which may cause
personal injury or damage to equipment.
7.Lower front axle.
CAUTION: Ensure brake hoses and ABS
sensor harnesses are not damaged when
lowering front axle.
8.Release and remove front spring from damper.Refit
1.Clean front spring seats.
2.Position front spring, with close coil uppermost,
over damper and locate in cut out in lower
spring seat.
3.Ensure both front springs are correctly located
in spring seats and raise front axle. Fit bolts
securing both dampers to front axle and tighten
to 45 Nm (33 lbf.ft).
4.Ensure washer is in place on lower ball joint of
each anti-roll bar link, then connect lower ball
joints to axle. Tighten nuts to 100 Nm (74 lbf.ft).
5.Fit front road wheels and tighten nuts to 140
Nm (103 lbf.ft).
6.Remove stands and lower vehicle.

FRONT SUSPENSION
REPAIRS 60-33
Wheel hub
$% 60.25.01
Remove
1.Release ABS sensor harness grommet from
inner wing valance and disconnect multiplug.
2.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.
3.Remove road wheel.
4.Pull ABS sensor harness through aperture into
wheel arch.5.Release harness from brackets on inner wing
valance, suspension turret and front hub.
6.Release stake from drive shaft nut.
7.With assistance, remove drive shaft nut.
Discard the nut.
8.Remove front brake disc.

+ BRAKES, REPAIRS, Brake disc -
front.
9.Remove 4 bolts securing wheel hub to steering
knuckle.
10.Release wheel hub from steering knuckle, then
remove wheel hub and drive shaft assembly
from axle.
CAUTION: Do NOT remove the ABS sensor
from the hub. The hub and the sensor are
supplied as an assembly.

FRONT SUSPENSION
60-34 REPAIRS
11.Position the wheel hub and drive shaft on a
press, place supports beneath the wheel studs
and press the drive shaft from the wheel hub.
12.Remove drive shaft oil seal from axle casing. Refit
1.Clean drive shaft oil seal recess, drive shaft
splines, oil seal running surface, wheel hub
and steering knuckle mating faces, ABS
sensor and sensor recess.
2.Lubricate lip of new drive shaft oil seal and
running surface on drive shaft with clean
differential oil.

+ CAPACITIES, FLUIDS,
LUBRICANTS AND SEALANTS,
Lubrication.
3.Use tool LRT-51-012 to fit new drive shaft oil
seal to axle casing.
4.Fit drive shaft to axle casing.
5.Apply anti-seize compound to wheel hub and
steering knuckle mating face.
M51 0057

FRONT SUSPENSION
REPAIRS 60-35
6.Apply a 3 mm (0.125 in) wide bead of sealant,
Part No. STC 50554 around drive shaft
circumference, as illustrated.
7.Ensure ABS harness is located in cut out in
steering knuckle.
8.Fit wheel hub to drive shaft and align steering
knuckle. The sealant will smear along the
length of the splines as the wheel hub is fitted
to the drive shaft.
9.Fit wheel hub bolts and tighten to 100 Nm (74
lbf.ft).
10.Fit new drive shaft nut and lightly tighten.
11.Fit front brake disc.

+ BRAKES, REPAIRS, Brake disc -
front.
12.With assistance, final tighten drive shaft nut to
490 Nm (360 lbf.ft). Stake drive shaft nut. The
drive shaft nut must be tightened before
sealant has cured.
13.Secure ABS sensor harness to brackets and
secure grommet to inner wing.
14.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
15.Remove stand(s) and lower vehicle.
16.Connect ABS sensor multiplug.
Damper - front
$% 60.30.02
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 road wheel.
3. RH damper: Release coolant reservoir and
position aside.
4.Loosen through bolt securing damper to turret.
WARNING: Make sure the axle cannot move
when the damper is disconnected. The
damper limits the downward movement of
the axle. If the axle is not restrained,
disconnecting the damper will allow
unrestricted movement which may cause
personal injury or damage to equipment.
M51 0058

FRONT SUSPENSION
60-36 REPAIRS
5.Remove 4 nuts securing turret base to chassis.
6.Remove 2 bolts securing damper to axle.
7. ACE models: Remove bolt securing ACE pipe
clamp to chassis.
8. ACE models: Remove bolt securing ACE pipe
clamp to turret.
9.Release harness clip from turret.
10.Raise turret and remove through bolt.
11.Compress damper and manoeuvre turret from
engine bay.
12.Remove damper. Refit
1.Position damper and manoeuvre turret into
position. Raise damper and align to turret. Fit
through bolt but do not tighten at this stage.
2.Align damper assembly to spring seat.
3.Fit bolts securing damper to axle and tighten to
45 Nm (33 lbf.ft).
4.Fit nuts securing turret to chassis and tighten
to 23 Nm (17 lbf.ft).
5.Tighten through bolt to 125 Nm (92 lbf.ft).
6. ACE models: Position ACE pipe clamp to
chassis and secure with bolt.
7. ACE models: Position ACE pipe clamp to
turret and secure with bolt.
8.Secure harness to turret.
9. RH damper: Reposition coolant reservoir.
10.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
11.Remove stand(s) and lower vehicle.

FRONT SUSPENSION
REPAIRS 60-37
Bushes - radius arm
$% 60.35.18
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 road wheel.
3.Remove and discard nut securing track rod to
steering knuckle.
4.Using LRT-57-036 break taper, release track
rod and position aside5.Remove and discard cable tie securing front
axle breather
6.Remove nut and bolt securing radius arm to
chassis.
7.Remove 2 nuts securing radius arm to axle.
8.Remove rear bolt from radius arm.
9.Remove front bolt from radius arm and remove
radius arm from axle.

FRONT SUSPENSION
60-38 REPAIRS
10.Using LRT-60-011/1 and LRT-60-011/2 press
out bush from rear end of radius arm.
11.Using a suitable piece of tubing, press out
bushes from axle end of radius arm.Refit
1.Clean and lubricate bush and radius arm
mating faces.
2.Using LRT-60-011/1,LRT-60-011/2 and LRT-
60-011/3, press bush into rear end of radius
arm.
3.Using a suitable piece of tubing press front
radius arm bush into radius arm.
4.Repeat above operation for remaining bush.
5.Position radius arm to vehicle and fit securing
nuts and bolts, do not tighten at this stage.
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.
6.Fit cable tie to secure axle breather.
7.Fit track rod to steering knuckle and secure with
nut, tighten to 125 Nm (92 lbf.ft).
8.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
9.Remove stand(s) and lower vehicle.
10.Tighten radius arm nuts and bolts to 230 Nm
(170 lbf.ft).

FRONT SUSPENSION
REPAIRS 60-39
ECU - ACE
$% 60.60.01
Remove
1.Remove BCU.

+ BODY CONTROL UNIT, REPAIRS,
Body control unit (BCU).
2.Remove 5 multiplugs from SLABS ECU.
3.Remove multiplug from ACE ECU.
4.Remove lower nut and loosen upper nut
securing SLABS and ACE ECU bracket to
body.
5.Remove ECU's and bracket assembly. 6.Remove 3 nuts securing ACE ECU and remove
ACE ECU.
Refit
1.Fit ACE ECU to bracket and secure with nuts.
2.Fit ECU's and bracket assembly to body and
secure with nuts.
3.Connect multiplugs to ACE ECU and SLABS
ECU.
4.Fit BCU.

+ BODY CONTROL UNIT, REPAIRS,
Body control unit (BCU).
5.If a replacement ACE ECU has been fitted, use
TestBook to calibrate ACE system.