2002 LAND ROVER DISCOVERY wheel bolts

FRONT SUSPENSION
60-32 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 60-33
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.

FRONT SUSPENSION
60-34 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
60-36 REPAIRS
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.
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 AND
LUBRICANTS, 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 60-37
6.Apply a 3 mm (0.125 in) wide bead of Loctite
640 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 Loctite 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
Loctite 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
60-38 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
60-40 REPAIRS
Refit
1.Clean bush locations in radius arm.
2.Press bushes into radius arm:
lUse LRT-60-011/1, LRT-60-011/2 and
LRT-60-011/3 to fit bush at rear of radius
arm.
3.Position radius arm to vehicle. Fit securing
bolts and nuts but do not tighten at this stage.
4.Fit track rod to steering knuckle. Fit and tighten
nut to 125 Nm (92 lbf.ft).
5.Fit road wheel and tighten nuts to 140 Nm (103
lbf.ft).
6.Remove stand(s) and lower vehicle.
7.Tighten radius arm nuts and bolts to 230 Nm
(170 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.
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.

FRONT SUSPENSION
REPAIRS 60-51
Solenoid - directional control valve - ACE
$% 60.60.24
Remove
1.Raise vehicle on a ramp.
2.Disconnect multiplug from solenoid.
3.Loosen cap securing solenoid to directional
control valve.
4.Remove 3 bolts securing valve block to
chassis, lower block sufficiently only to remove
solenoid.
5.Remove cap securing solenoid to directional
control valve and discard 'O' ring.
6.Remove solenoid from directional control valve
and discard 'O' ring from base of valve.
Refit
1.Ensure solenoid and directional control valve
are clean.
2.Fit new 'O' ring to base of directional control
valve.
3.Fit solenoid to directional control valve, with
arrow on solenoid pointing up and connector in
correct position.
4.Fit new 'O' ring to solenoid securing cap. Fit cap
to solenoid but do not tighten at this stage.
5.Fit 3 bolts securing valve block to chassis and
tighten to 18 Nm (13 lbf.ft) .
6.Tighten solenoid securing cap to 11 Nm (8
lbf.ft) .
7.Connect multiplug to solenoid.
8.Lower vehicle.
Pipe assembly - valve block to front
actuator - ACE
$% 60.60.31
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.
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 RH front road wheel.
3.Remove 7 screws securing RH front wheel arch
liner extension and remove extension.