Discovery 2. Manual — part 177

STEERING

REPAIRS

57-43

Steering column assembly and lock

$% 57.40.01

Remove

1. Remove steering column intermediate shaft.

+

STEERING, REPAIRS, Shaft -

intermediate and universal joint - steering
column.

2. Remove rotary coupler.

+

RESTRAINT SYSTEMS, REPAIRS,

Rotary coupler.

3. Open fascia lower access panel.
4. Remove steering column nacelle.

+

STEERING, REPAIRS, Nacelle -

steering column.

5. Disconnect multiplug and illumination bulb

from passive coil and remove passive coil.

6. Disconnect 2 multiplugs from wiper switch

assembly.

7. Disconnect 2 multiplugs from light switch

assembly.

8. Loosen screw and remove switch assembly.
9. Disconnect ignition switch multiplug.

10. Disconnect multiplug from ignition switch

housing.

11. Release harness from column clip.

STEERING

57-44

REPAIRS

12. Remove 4 nuts securing steering column

assembly to fascia rail and remove steering
column assembly.

13. Remove rubber boot from steering column

assembly.

14. Position steering column assembly in a vice.
15. Remove 2 screws and remove ignition switch.
16. Remove cable tie and remove multiplug from

ignition switch.

17. Centre punch or drill out steering lock shear

bolts.

18. Remove steering lock

Refit

1. Position lock to steering column assembly and

fit shear bolts. Do not tighten shear bolts at this
stage.

2. Insert starter key, check operation of steering

lock and that key turns freely.

3. Tighten shear bolts fully and shear heads off.
4. Position ignition switch to column, fit and

tighten screws.

5. Position multiplug to switch and secure with

new cable tie.

6. Fit rubber boot to column.
7. Remove column from vice.
8. Position steering to fascia rail fit nuts and

tighten to 22 Nm (16 lbf.ft).

9. Secure harness to column clip.

10. Position rubber grommet.
11. Close access panel and secure turn buckles.
12. Connect ignition switch multiplugs.
13. Position column switch and tighten clamp

screw.

14. Connect column switch multiplugs.
15. Position passive coil, connect multiplug and

illumination bulb.

16. Fit steering column nacelle.

+

STEERING, REPAIRS, Nacelle -

steering column.

17. Fit rotary coupler.

+

RESTRAINT SYSTEMS, REPAIRS,

Rotary coupler.

18. Close fascia lower access panel.
19. Fit steering column intermediate shaft.

+

STEERING, REPAIRS, Shaft -

intermediate and universal joint - steering
column.

STEERING

REPAIRS

57-45

Shaft - intermediate and universal joint -
steering column

$% 57.40.22

The intermediate shaft has a red indicator clip
fitted which must be inspected at service, and
after the vehicle has been subject to an impact.
If the clip is not present or is not fully seated
against the clamp plate, a new assembly must be
fitted.

Remove

1. LHD diesel: Loosen 2 clips securing

intercooler to turbocharger hose. Place hose
aside.

2. Remove bolt securing intermediate shaft to

steering column.

3. Remove bolt securing intermediate shaft to

universal joint.

4. Universal joint: Remove the bolt securing the

universal joint to the steering box.

STEERING

57-46

REPAIRS

5. Ensure steering wheel is in the straight ahead

position and fit centralising bolt to steering box.
Remove the key from the ignition switch

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. Intermediate shaft: Slide the intermediate

shaft upwards, release from the universal joint
and remove intermediate shaft from the
steering column.

7. Universal joint: Slide the intermediate shaft

upwards, release from the universal joint and
remove universal joint from the steering box.

Refit

1. Clean and inspect splines for wear and

damage.

2. Intermediate shaft: Locate intermediate shaft

on steering column and engage with universal
joint. Ensure splines are fully engaged and bolt
holes aligned.

3. Universal joint: Locate universal joint on

steering box and engage in intermediate shaft.
Ensure splines are fully engaged and bolt
holes aligned.

4. Fit bolts securing intermediate shaft to

universal joint and tighten to 25 Nm (18 lbf.ft).

5. Intermediate shaft: Fit bolts securing

intermediate shaft to steering column and
tighten to 25 Nm (18 lbf.ft).

6. Universal joint: Fit bolts securing universal

joint to steering box and tighten to 25 Nm (18
lbf.ft).

7. LHD diesel: Connect hose to turbocharger

and intercooler and secure the clips.

8. Fit ignition key, remove steering box

centralising bolt and check that steering wheel
is in the straight ahead position.