Discovery (1995+): Body Repair Manual — part 16
76
CHASSIS AND BODY
2
REPAIR
FRONT DOOR TRIM PANEL
Service repair no - 76.34.01
Remove
1. Remove the two securing screws and detach the
door pull from its mounting brackets on the inner
door panel.
2. Remove the interior door handle finisher button
to reveal the screw retaining the handle
surround.
3. Remove the screw and detach the handle
surround from the trim panel.
4. Where applicable remove the window winder.
5. Detach the trim panel by inserting a trim panel
removing tool between the trim panel and the
inner door panel, gently prise out the fourteen
plastic securing clips from their respective holes
in the inner door panel.
6. Disconnect the two speaker connections from
inside the door and remove the trim panel
complete with speaker, and door bin.
7. If a new trim panel is to be fitted, remove the
speaker, door bin and remote button finisher
from the existing trim panel and fit them to the
new panel.
Refit
8. Reverse removal procedure.
FRONT DOOR GLASS AND REGULATOR
Service repair no - 76.31.45
Remove
1. Ensure the window is in the fully closed position
and secure with adhesive tape to prevent the
window from dropping down.
2. Disconnect battery negative lead.
3. Remove the door trim panel.
See this section.
4. Remove the plastic vapour barrier.
5. Where applicable remove the window lift motor.
See ELECTRICAL, Repair.
6. Remove the four window regulator retaining
screws and shakeproof washers from the inner
door panel.
7. Remove the two screws and shakeproof
washers retaining the lower window lift channel,
and slide the channel off the stud.
CHASSIS AND BODY
3
REPAIR
8. Disengage the lifting arm stud from the upper
lifting channel, manoeuvre the window regulator
and remove it from the lower centre opening in
the inner door panel.
9. Remove the exterior driving mirror.
See
ELECTRICAL, Repair.
10. Remove the waist rail seal from the top of the
door panel.
11. Remove the ’Torx’ bolt from the hinge face of the
door which secures the front of the door frame.
12. Remove the bolt and plain washer from the
opening edge of the door which secures the rear
of the door frame.
13. Remove the bolt and plain washer from the
recessed hole in the front of the inner door panel
under the exterior driving mirror mounting plate.
14. Remove the screws and plain washers, from
inside the door, securing the bottom of the front
and rear glass channels.
15. Lift the door glass frame complete with glass out
of the door panel and remove to a suitable
bench.
16. Remove the adhesive tape securing the glass to
the door frame.
17. Slide the glass out of the door frame channel.
Refit
NOTE: When refitting the door glass
frame, ensure it is repositioned to suit the
door opening before fully tightening the
door frame securing bolts.
18. Reverse removal procedure.
76
CHASSIS AND BODY
4
REPAIR
FRONT DOOR LOCK, OUTSIDE AND INSIDE
DOOR RELEASE HANDLES
Service repair no - 76.37.12/31
Remove
1. Disconnect battery negative lead.
2. Remove the door trim panel.
See this section.
3. Remove the door glass and regulator.
See this
section.
4. Where applicable remove the door actuator unit.
See ELECTRICAL, Repair.
5. Disconnect the lock barrel control rod from the
lock by releasing the metal clip at the bottom of
the rod.
6. Disconnect the control rod from the outside door
release handle by pulling it out of the plastic
ferrule.
7. Disconnect the remote button control rod from
the lock by releasing the metal clip at the bottom
of the rod and withdraw the rod from the door.
8. Disconnect the control rod connector between
the inside door release handle and the door lock
by releasing the metal clip and pulling one of the
control rods out of the plastic connecting block.
This is accessible through the small centre
cut-out in the door panel. The control rod also
passes through a guide bracket in the inside of
the inner door panel.
9. From inside the door panel push out the small
pin that secures the quadrant to the inner door
panel. Push the quadrant out of the panel.
10. Release the door lock by removing the two
counter-sunk screws from the door edge and the
single screw and shakeproof washer on the
inner door panel.
CHASSIS AND BODY
5
REPAIR
11. Withdraw the lock through the lower rear cut-out
on the inner door panel.
12. Remove the two nuts, shakeproof washers and
retaining bracket securing the outer door release
handle to the outer door panel, accessible
through the upper rear cut-out on the inner door
panel.
13. Carefully detach the door release handle from
the outer panel.
14. Remove the two screws securing the inside door
release handle to the inner panel.
15. Withdraw the handle from its location with the
connecting rod half still attached.
16. Unclip the end of the connecting rod from the
handle.
Refit
17. Reverse removal procedure.
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