Discovery 2. Manual — part 610

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

REPAIRS

60-39

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 nut securing track rod to steering

knuckle. Use LRT-57-036 to break taper, then
release track rod and position aside.

4. Remove nut and bolt securing radius arm to

chassis.

5. Remove nuts securing radius arm to axle.

Remove rear bolt and lower the radius arm.
Remove front bolt and remove radius arm from
vehicle.

6. Press out bushes from axle end of radius arm

using a length of steel tubing.

7. Press out bush from rear of radius arm:

l

Use LRT-60-011/1 and LRT-60-011/2 to
remove bush.

FRONT SUSPENSION

60-40

REPAIRS

Refit

1. Clean bush locations in radius arm.

2. Press bushes into radius arm:

l

Use 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.