Discovery 2. Manual — part 608

FRONT SUSPENSION

REPAIRS

60-29

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

60-30

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.

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.

FRONT SUSPENSION

REPAIRS

60-31

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

60-32

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.